Hardi NAVIGATOR FORCE Instruction Book

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NAVIGATOR FORCE

Original

Instruction book

67039600-100 - Version 1.00 GB - 05.2014

www.hardi-international.com

We congratulate you for choosing a HARDI plant protection product. The reliability and efficiency of this product depend upon your care. The first step is to carefully read and pay attention to this instruction book. It contains essential information for the efficient use and long life of this quality product.

The original instruction book is approved and published in English. All other languages are translations of the original book. In the event of any conflicts, inaccuracies or deviations between the English book and other languages, the English version shall prevail.

Illustrations, technical information and data in this book are believed to be correct at the time of printing. As it is the policy of HARDI INTERNATIONAL A/S to continuously improve our products, we reserve the right to make changes in design, features, accessories, specifications and maintenance instructions at any time and without notice.

HARDI INTERNATIONAL A/S is without any obligation in relation to implements purchased before or after such changes.

HARDI INTERNATIONAL A/S cannot undertake any responsibility for possible omissions or inaccuracies in this publication, although everything possible has been done to make it complete and correct.

As this instruction book covers more models and features or equipment, which are available in certain countries only, please pay attention to paragraphs dealing with precisely your model.

Published and printed by HARDI INTERNATIONAL A/S.

This book covers NAVIGATOR 5000 and 6000 litre models.

1 - EU Declaration

EU Declaration of Conformity

As manufacturer:

HARDI INTERNATIONAL A/S

Herthadalvej 10

4840 Nørre Alslev

DENMARK

hereby declare that the following product

* Further data for this sprayer are shown on its type sign.

fulfils all the relevant provisions of the following Directives of the European Parliament and of the Council:

• 2006/42/EC, regarding the Machinery Directive (CE marking).

• 2009/127/EC and later amendments, regarding machinery for pesticide application.

• 2014/30/EU, regarding electromagnetic compatibility (EMC). Electronic components on the machine are tested and

installed according to the requirements of the EMC Directive.

as well as the following ISO standard:

• ISO 14982, regarding test methods and acceptance criteria for electromagnetic compatibility for agricultural machinery.

Field sprayer:

Identification number*:

HARDI INTERNATIONAL A/S Nørre Alslev, Denmark

Date: Signature:

Name:

Job title:

1 - EU Declaration

Table of Contents

1 - EU Declaration

EU Declaration of Conformity ................................................................................................................3

2 - Safety Notes

Operator Safety .....................................................................................................................................9

Symbols ........................................................................................................................................................................................................................ 9

Precautions ................................................................................................................................................................................................................ 9

Label Explanation ................................................................................................................................................................................................ 10

3 - Description

General Info .........................................................................................................................................13

View ............................................................................................................................................................................................................................. 13

Identification Plates ........................................................................................................................................................................................... 15

Roadworthiness ................................................................................................................................................................................................... 15

Sprayer Use ............................................................................................................................................................................................................. 15

Frame .......................................................................................................................................................................................................................... 15

Tanks and Equipment ...................................................................................................................................................................................... 15

Liquid System ......................................................................................................................................16

Pump .......................................................................................................................................................................................................................... 16

Valves and Symbols ........................................................................................................................................................................................... 16

DynamicFluid4 Pressure Regulation ....................................................................................................................................................... 17

RinseTank ................................................................................................................................................................................................................. 20

Filters ........................................................................................................................................................................................................................... 21

EasyClean Filter ..................................................................................................................................................................................................... 21

CycloneFilter .......................................................................................................................................................................................................... 22

TurboFiller ................................................................................................................................................................................................................ 23

Clean Water Tank ................................................................................................................................................................................................ 24

DilutionKit (optional) ......................................................................................................................................................................................... 24

BoomPrime (optional) ...................................................................................................................................................................................... 25

Diagram - Basic Liquid System ................................................................................................................................................................... 26

Diagram - Liquid System with Options ................................................................................................................................................. 27

Hydraulic Systems ...............................................................................................................................28

Hydraulic Blocks ................................................................................................................................................................................................... 28

IntelliTrack Hydraulics (optional) ............................................................................................................................................................... 29

Boom ...................................................................................................................................................30

Boom and terminology ................................................................................................................................................................................... 30

Equipment ...........................................................................................................................................31

ManualTrack ........................................................................................................................................................................................................... 31

IntelliTrack ................................................................................................................................................................................................................ 31

Driving Technique for IntelliTrack ............................................................................................................................................................. 31

Platform ..................................................................................................................................................................................................................... 32

Right Side Cover .................................................................................................................................................................................................. 32

Tank Level Indicator ........................................................................................................................................................................................... 32

Nozzle Pressure Gauge .................................................................................................................................................................................... 33

ChemLocker (optional) .................................................................................................................................................................................... 33

SafetyLocker (optional) .................................................................................................................................................................................... 33

Night Spraying Light (optional) ................................................................................................................................................................. 34

External Cleaning Device (optional) ........................................................................................................................................................ 34

EcoFill (optional) .................................................................................................................................................................................................. 34

4 - Sprayer setup

General info .........................................................................................................................................35

Unloading the Sprayer from the Truck .................................................................................................................................................. 35

Pulling the Sprayer at the Tie Down Points ........................................................................................................................................ 35

Before Putting the Sprayer into Operation ......................................................................................................................................... 35

Support Leg ............................................................................................................................................................................................................ 36

Jack Up the Sprayer ........................................................................................................................................................................................... 36

Table of Contents

Transmission Shaft ..............................................................................................................................37

Operator Safety .................................................................................................................................................................................................... 37

PTO Installation ..................................................................................................................................................................................................... 37

Mechanical Connections ......................................................................................................................38

Drawbars .................................................................................................................................................................................................................. 38

Fixed Drawbar (High Hitch Extension only) ........................................................................................................................................ 39

Tracking Drawbar Transport Lock ............................................................................................................................................................. 39

Hose Package Support .................................................................................................................................................................................... 40

Hydraulic Systems ...............................................................................................................................41

General Info ............................................................................................................................................................................................................ 41

Requirements for tractor ................................................................................................................................................................................ 41

Open Centre Hydraulics (optional) .......................................................................................................................................................... 42

Electrical Connections .........................................................................................................................43

IntelliTrack Potentiometer Connection ................................................................................................................................................. 43

Power Supply ......................................................................................................................................................................................................... 43

Installation of Control Unit Brackets ........................................................................................................................................................ 44

Road Safety Kit (optional) ............................................................................................................................................................................... 44

Label for Manually Steered Version (optional) .................................................................................................................................. 45

Speed Transducer for Sprayer ..................................................................................................................................................................... 45

Liquid System ......................................................................................................................................46

Label for DilutionKit (optional) ................................................................................................................................................................... 47

BoomPrime Adjustment (optional) ......................................................................................................................................................... 48

Track width, axles and wheels .............................................................................................................49

Altering the Track Gauge (optional) ........................................................................................................................................................ 49

Turning the Wheel Rim ................................................................................................................................................................................... 49

Counter Weight .................................................................................................................................................................................................... 50

Brakes ..................................................................................................................................................51

Emergency and Parking Brake (optional) ............................................................................................................................................. 51

Hydraulically Activated Brakes (optional) ............................................................................................................................................. 51

Air Activated Brakes (1st option) ............................................................................................................................................................... 52

Air Activated Brakes (2nd option) ............................................................................................................................................................. 52

Single-Line Air Brakes (optional) ................................................................................................................................................................ 53

Dual-Line Air Brakes (optional) ................................................................................................................................................................... 53

5 - Operation

General Info .........................................................................................................................................55

Environmental Info ............................................................................................................................................................................................ 55

Boom ...................................................................................................................................................56

Safety Info ................................................................................................................................................................................................................ 56

Manoeuvring of the Boom ( HPZ ) - with HC 6500 / HC 8500 / HC 9500 / ISOBUS ................................................... 57

Hydraulic Slanting Control (Optional) .................................................................................................................................................... 58

Boom Tilt Function ............................................................................................................................................................................................. 58

Night Spraying Light (optional) ................................................................................................................................................................. 58

Liquid System ......................................................................................................................................59

Filling/Washing Location Requirements .............................................................................................................................................. 59

Filling of Water ...................................................................................................................................................................................................... 59

Filling Through Tank Lid ................................................................................................................................................................................. 60

External Filling Device (optional) ............................................................................................................................................................... 60

Filling of Rinsing Tank (optional) ............................................................................................................................................................... 61

Filling of Clean Water Tank ............................................................................................................................................................................ 61

Safety Precautions - Crop Protection Chemicals ............................................................................................................................. 62

Filling Chemicals through Tank Lid ......................................................................................................................................................... 62

Filling Liquid Chemicals by using HARDI TurboFiller .................................................................................................................... 63

Filling Powder Chemicals by using HARDI TurboFiller ................................................................................................................ 64

Agitation before Resuming a Spray Job ............................................................................................................................................... 65

Parking the Sprayer ............................................................................................................................................................................................ 65

TurboFiller Rinsing .............................................................................................................................................................................................. 67

Table of Contents

Cleaning ...............................................................................................................................................69

Quick Reference - Cleaning .......................................................................................................................................................................... 70

Standard Cleaning .............................................................................................................................................................................................. 70

Cleaning the Tank and Liquid System ................................................................................................................................................... 71

Cleaning and Maintenance of Filters ...................................................................................................................................................... 71

Use of Rinsing Tank and Rinsing Nozzles (Optional) ..................................................................................................................... 72

Technical Residue .............................................................................................................................................................................................. 73

Using the Drain Valve ....................................................................................................................................................................................... 73

Pressure Draining (optional) ......................................................................................................................................................................... 74

Outside Cleaning - Use of External Cleaning Device (optional) ............................................................................................ 74

6 - Maintenance

Lubrication ..........................................................................................................................................75

Recommended Lubricants ........................................................................................................................................................................... 75

Boom lubrication & oiling plan ................................................................................................................................................................... 76

Trailer/ParaLift Lubrication & Oiling Plan .............................................................................................................................................. 77

PTO Lubrication & Oiling Plan ..................................................................................................................................................................... 77

Service and Maintenance Intervals .....................................................................................................78

10 Hours Service - EasyClean Filter .......................................................................................................................................................... 78

10 Hours Service - CycloneFilter ................................................................................................................................................................ 79

10 Hours Service - In-Line Filter (optional) .......................................................................................................................................... 79

10 Hours Service - Spraying Circuit .......................................................................................................................................................... 80

10 Hours Service - Brakes (optional) ........................................................................................................................................................ 80

10 Hours Service - Air Tank for Brakes (optional) ............................................................................................................................. 80

50 Hours Service - Transmission Shaft ................................................................................................................................................... 80

50 Hours Service - Wheel Nuts ................................................................................................................................................................... 80

50 Hours Service - Air Brakes (optional) ................................................................................................................................................ 80

50 Hours Service - Tyre Pressure ................................................................................................................................................................ 80

100 Hours Service - Check/Adjust Drawbar (Fixed High Drawbar only) ........................................................................... 81

250 Hours Service - Readjustment of the Boom ............................................................................................................................. 81

250 Hours Service - Hydraulic Circuit ...................................................................................................................................................... 81

250 Hours Service - Hoses and Tubes .................................................................................................................................................... 81

250 Hours Service - Wheel Bearings ........................................................................................................................................................ 81

250 Hours Service - Inspect Parking Brake (optional) ................................................................................................................... 82

250 Hours Service - Brake Adjustment (optional) ........................................................................................................................... 82

250 Hours Service - Hydraulic Brakes (optional) .............................................................................................................................. 83

1000 Hours Service - Wheel Bearings and Brakes ........................................................................................................................... 83

Occasional Maintenance ......................................................................................................................85

Pump Valves and Diaphragms Renewal ............................................................................................................................................... 85

Level Indicator Adjustment .......................................................................................................................................................................... 86

Level Indicator Cord Renewal ..................................................................................................................................................................... 86

Drain Valve Seal Replacement .................................................................................................................................................................... 86

Nozzle Tubes and Fittings ............................................................................................................................................................................. 87

Adjustment of 3-Way Valve .......................................................................................................................................................................... 87

Retighten the Frame ......................................................................................................................................................................................... 87

Readjustment of Boom - General Info ................................................................................................................................................... 88

Alignment of inner and 1st outer wings .............................................................................................................................................. 88

Alignment of 1st outer and 2nd outer wings ................................................................................................................................... 89

Breakaway section adjustment .................................................................................................................................................................. 89

End stop valves ..................................................................................................................................................................................................... 89

Wing tilt adjustment ......................................................................................................................................................................................... 90

Slanting Indicator Adjustment (optional) ............................................................................................................................................ 90

Wear Bushing Replacement on Boom Lift .......................................................................................................................................... 90

Wear Bushing Renewal on Steering ........................................................................................................................................................ 91

Venting the Steering Hydraulics ................................................................................................................................................................ 91

Table of Contents

Suspension Rubber Dampers (optional) .............................................................................................................................................. 91

Shield Replacement on Transmission Shaft ....................................................................................................................................... 91

Replacement of Transmission Shaft Cross Journals ...................................................................................................................... 91

Change of Tyres ................................................................................................................................................................................................... 92

IntelliTrack Front Potentiometer Calibration ..................................................................................................................................... 93

Safety Valve Activation .................................................................................................................................................................................... 94

Off-Season Storage ..............................................................................................................................95

Off-Season Storage Program ....................................................................................................................................................................... 95

7 - Fault finding

Operational Problems .........................................................................................................................97

Liquid System ........................................................................................................................................................................................................ 98

Hydraulic System, Z-boom version .......................................................................................................................................................... 99

Mechanical problems ....................................................................................................................... 100

Emergency Operation - Hydraulics ........................................................................................................................................................100

Emergency Operation - Liquid system ................................................................................................................................................100

8 - Technical specifications

Dimensions ....................................................................................................................................... 101

Overall Dimensions ..........................................................................................................................................................................................101

Weight .....................................................................................................................................................................................................................102

Wheel and Axle Dimensions ......................................................................................................................................................................102

Pump Specifications ......................................................................................................................... 103

Pump Model 363/5.5 ......................................................................................................................................................................................103

Pump Model 363/10.0 ...................................................................................................................................................................................103

Pump Model 463/5.5 ......................................................................................................................................................................................103

Pump Model 463/6.5 ......................................................................................................................................................................................103

Pump Model 463/10.0 ...................................................................................................................................................................................103

Pump Model 463/12.0 ...................................................................................................................................................................................104

Filters and Nozzles ............................................................................................................................................................................................104

Temperature and Pressure Ranges ........................................................................................................................................................104

Brakes ........................................................................................................................................................................................................................105

Power Consumption .......................................................................................................................................................................................105

Airborne Noise Emission ...............................................................................................................................................................................105

Tyre Pressure ........................................................................................................................................................................................................106

Materials and Recycling .................................................................................................................... 107

Disposal of the Sprayer ..................................................................................................................................................................................107

Electrical Connections ...................................................................................................................... 108

Electrical Connections for SPRAY II ........................................................................................................................................................108

Rear Lights .............................................................................................................................................................................................................108

Electric Connections for Boom and Work Lights ..........................................................................................................................109

Boom hydraulic - HPZ 2-fold ......................................................................................................................................................................110

Boom hydraulic - HPZ 3-fold ......................................................................................................................................................................110

Sprayer Hydraulics, Z-version IntelliTrack ...........................................................................................................................................111

Sprayer Hydraulics, Z-version ManualTrack ......................................................................................................................................111

......................................................................................................................................................................................................................................112

Index

Index ................................................................................................................................................. 113

2 - Safety Notes

Operator Safety

Symbols

These symbols are used throughout the book to designate, where the reader has to pay extra attention. The four symbols have the following meanings.

€

This symbol means DANGER. Be very alert as your safety is involved!

This symbol means WARNING. Be alert as your safety can be involved!

This symbol means ATTENTION. This guides to better, easier and more safe operation of your sprayer!

This symbol means NOTE. Extra information is provided.

Precautions

Please note the following recommended precautions and safe operating practices, before using the sprayer.

General Info

€

Read and understand this instruction book, before using the equipment. It is equally important, that other operators of this equipment read and understand this book.

If any portion of this instruction book remains unclear after reading it, contact your HARDI dealer for further explanation before using the equipment.

€

Local law may demand, that the operator is certified to use spray equipment. Adhere to the local law.

€

The driver seat in the tractor is the intended working place during operation.

€

Wear protective clothing. Clothing may differ depending on the chemical being sprayed. Adhere to the local law.

Wash and change clothes after spraying. Wash tools if they have become contaminated.

€

Do not eat, drink or smoke while spraying or working with contaminated equipment.

In case of poisoning, immediately seek medical advice. Remember to identify the chemicals used.

Filling and Spraying

€

No persons are allowed in the operation areas of the sprayer. Be careful not to hit people or surroundings when manoeuvring the sprayer, especially when reversing.

€

Slow down when driving in uneven terrain, as the machine might be in risk of turning over.

€

Keep children away from the equipment!

€

Do not attempt to enter the tank.

€

Do not walk under any part of the sprayer unless it is secured. The boom is secured when placed in the transport brackets.

2 - Safety Notes

Service

€

Pressure test with clean water prior to filling with chemicals. Never dismount the hoses if the machine is in operation.

DANGER! Do not exceed the maximum recommended speed (rpm) for the Power Take-Off (PTO).

€

Rinse and wash equipment after use and before servicing.

€

Never service or repair the equipment while it is operating. Always reassemble all safety devices or shields immediately after servicing.

€

Disconnect electrical power before servicing and depressurize equipment after use and before servicing.

€

If arc welding is used on the equipment, or anything connected to the equipment, disconnect power leads before welding. Remove all inflammable or explosive material from the area.

€

The External Cleaning Device should not be used, if important parts of the equipment have been damaged, including safety devices, high pressure hoses etc.

Label Explanation

The labels are designating potential dangerous places on the machine. Anybody working with or being in close range of the sprayer must respect these labels!

The labels should always be clean and readable! Worn or damaged labels must be replaced with new ones. Contact your local dealer for new labels.

Note that not all labels shown here will apply to your sprayer.

Chemical handling!

Carefully read the informations about chemical preparation before handling the machine. Observe instructions and safety rules when operating.

Service!

Carefully read operators instruction book before handling the machine. Observe instructions and safety rules when operating.

Service!

Shut off the engine and remove ignition key before performing maintenance or repair.

Service!

Tighten to the torque according to instruction book.

Risk of death!

Do not attempt to enter tank.

Risk of burn!

Stay clear of hot surfaces.

Risk of injury!

Do not open or remove safety shields while engine is running.

Risk of injury!

Flying objects - keep a safe distance from the machine, as long as the engine is running.

Risk of injury!

Keep sufficient distance away from electrical power lines.

Risk of injury!

Keep hands away.

2 - Safety Notes

Risk of squeezing!

Stay clear of raised and unsecured loads.

Risk of squeezing

Never reach into the crushing danger area, as long as the parts are moving.

Risk of squeezing!

Keep hands away, when parts is moving.

Risk of falling off!

Do not ride on platform or ladder.

Risk of sprayer tipping over!

Be aware when disconnecting the sprayer.

Grapping area!

Manual handling of the boom etc.

Not for drinking!

This water must never be used for drinking.

Not for drinking!

This water must never be used for drinking.

Tank under p ressure!

Beware when moving lid.

EasyClean filter service!

Open and clean filter monthly.

Lifting point! Lifting point!

Load index!

Max. permitted load rating is 164 at 40 km/h.

2 - Safety Notes

3 - Description

General Info

View

1. EcoFill Valve (optional)

2. Tank Tube R i ser Pi pe Lid

3. Rinsing Tank Level Indicator

4. Main Tank Level Indicator

5. Main Tank Lid

6. EasyClean Filter Clogging Indicator

7. Spray Pressure Gauge

8. Clean Water Tank Lid

9. SafetyLocker

10. Parking Brake

11. Pump

12. Drawbar Hitch

13. Support Leg

14. Step to Platform

15. Agitation/External Cleaning Device Valve

16. Pressure SmartValve

17. External Filling ON/OFF Valve

18. Suction Valve

19. External Filling Coupler

20. EasyClean Filter

21. Rinsing Tank Coupler

22. Pressure Draining Coupler

23. TurboFiller Valves

24. TurboFiller

3 - Description

View

25. RinseTank

26. Main Tank

27. Hose Reel for External Cleaning Device

28. ChemLocker with FoamMarker Tank

29. CycloneFilter

30. Support Leg Storing Position

3 - Description

Identification Plates

Frame, boom centre frame and other main steel components have identification plates indicating type and part number. (not illustrated)

REFERENCE NO. is the main reference number of the complete machine.

A CE identification plate fitted on the frame indicates manufacturer name, model, sprayer weights, etc.

The identification plate also has a QR-code, which can be read by e.g. smartphones to obtain more detailed data about the sprayer, which can be useful for service staff.

Roadworthiness

When driving on public roads and in other areas, where the highway code applies, or in areas with special rules and regulations for marking and lights on implements, you should observe these and equip implements accordingly.

ATTENTION! Max. driving speed for models without brakes and for models equipped with brakes is different. Be aware that these speeds may differ due to local law. Contact local authorities for information of max. driving speeds!

Sprayer Use

The HARDI sprayer is for the application of crop protection chemicals and liquid fertilisers. The equipment must only be used for this purpose. It is not allowed to use the sprayer for any other purposes. If no local law demands that the operator must be certified to use spray equipment, it is strongly recommended to be trained in correct plant protection and in safe handling of plant protection chemicals to avoid unnecessary risk for persons and the environment, when carrying out your spray job.

Frame

Very strong and compact frame which also has a strong chemical and weather resistant electrostatic lacquer coat. Screws, nuts, etc. have been DELTA-MAGNI treated to be resistant to corrosion.

Tank s an d Eq u i p m e nt

The main tank made of impact-proof, UV-resistant and chemical resistant polyethylene, has a purposeful design with no sharp corners for easy cleaning. The filling hole is placed so it can be accessed from the platform. This ensures an easy access for the filling of sprays, cleaning of the tank, etc. The sprayer is also equipped with a rinsing tank and a clean water tank. An optional large, easy-to-read tank level indicator can be placed besides the platform, and it is visible from the tractor cabin.

Nominal contents are 5000 or 6000 litres.

HARDI-INTERNATIONAL AS

REFERENCE NO.:

3 - Description

Liquid System

Pump

Diaphragm pump with 6 diaphragms, model 363 or 463.

Standard = 540 rpm (6 splines shaft). Optional = 1000 rpm (21 splines shaft). The design of the diaphragm pump is simple, with easily accessible diaphragms and valves, which ensure that liquid does not contact the vital parts of the pump.

Valves and Symbols

The possible functions of valves are distinguished by coloured identification on the function labels. The modular valve system facilitates the addition of optional extras on both pressure side and suction side. A function is activated by turning the handle towards the desired function.

ATTENTION! Only the functions used should be open - always close remaining valves.

ATTENTION! If a valve is too tight to operate - or to loose (= liquid leakage) - the valve needs to be serviced. Please see “Adjustment of 3-Way Valve” on page 87 for further information.

Pressure SmartValve (Green Symbols)

This valve is to select which function the pressurized liquid from the pump will be routed to.

The active function is indicated by the indicator. The handle is turned so the indicator points to the label for required function. If handle is turned to a position without label (unused function) then the valve is closed.

Suction Valve (Blue symbols)

This valve is to select suction from main tank or from the rinsing tank.

The handle is turned so the label for required function is directed to the indicator. If handle is turned to vertical position (indicator not pointing at a label) then the valve is closed.

Agitation Valve (Green symbols)

With the adjustable Agitation valve it is possible to combine spraying with a high volume rate at high pressure with agitation at the same time.

This is controlled continuously by the valve: The valve is marked with an arrow on the disc that indicates the amount of liquid that passes through the valve.

• Handle is turned to a position near the tip of the arrow: Only a small amount of liquid is allowed to pass the valve resulting to a lesser extent of agitation.

Main tank Spraying

IInternal tank cleaning (Rinsing nozzles) (optional)

Pressure draining (optional) or TurboFiller (optional)

Main tank Rinsing tank (optional)

3 - Description

• Handle is turned to a position in the wide end of the arrow: A large amount of liquid will pass the valve resulting to a large extent of agitation.

External Filling Device Valve (Blue symbol) (optional)

The valve is used when filling from an external tank or reservoir. Activating valve, starts/stops the filling process.

NOTE! that the suction valve must be closed for maximum filling capacity.

DynamicFluid4 Pressure Regulation

Traditional fluid regulation starts, when the nozzles are opened. With DynamicFluid4 (DF4), the regulation is a continuous process, even if the nozzles are closed. Two ceramic discs regulate the pressure and ensure quick reaction and zero leakages. Used parameters are sprayer speed, PTO speed and the number of activated sections. The benefit is more precise application rates from the second the sprayer begins spraying.

The DynamicFluid4 uses feed forward technology based on 5 sensors, which feed the JobCom computer with data necessary for optimal regulation. It auto-primes at start-up and starts to move the valve towards the final position, immediately after the operator makes changes. For example, when section valves are opened or closed, the regulation valve is started at the same time as the section valve motors are started. This avoids overpressure situations e.g. after running empty and refilling of the main tank.

The 5 sensors are also back-up for each other, ensuring that the system can continue regulation - even if one or more sensor signals fails. The applied sensors measure:

• Sprayer speed (km/h)

• Fluid flow (l/min)

• Fluid pressure (bar)

• Pump speed (rpm)

• Regulation valve opening angle (°)

Features for DF4

• Very fast and accurate regulation when all sensors are ok, setup in menus are correct, and pump, filters and valves are in good condition.

• Quick reacting valve, when sections are turned ON/OFF, and at speed changes.

• Optimized AutoSectionControl feature that predict boom sections to open and optimized nozzle pressure.

• Optimized for different PTO systems.

• Nozzle surveillance. No setup or tuning is required for nozzle change.

• Warning in display, if failures occur on boom plumbing, such as severe clogging of line or nozzle filters or because of

large leakages on hoses and fittings.

• All functions work through with degraded performance (Limp-home modes), if:

• Failures occur in fluid system, e.g. pump defects, clogged filters or leaking valves.

• Failures occur on pressure sensor, flow sensor or pump sensor.

• There is a wrong setup of sprayer data in the menus.

• Emergency mode, if angle sensor or sprayer speed sensor fails.

Adjustable Agitation External Cleaning Device

(optional equipment)

External filling

3 - Description

Screen icons

The sprayer driver selects one of three modes: Auto, Manual or Increment Steps. The sprayer computer detects one of three regulation modes: Drop, Question Mark or Calibration Jug. This makes 9 modes in total.

Auto Manual Increment Steps

Automatic Volume Rate.

Manual Pressure Control.

Volume Rate is changed in steps as %-up or %-down.

Press a button on the controller box to select regulation mode.

Calibration Jug

Flow to the section valves.

Nozzle size (l/min at 3 bar) has been calculated.

Drop

No flow to the section valves.

The pump is not started, or the pressure SmartValve is set to another function than spraying.

Question Mark

Flow to the section valves, but pressure and flow has not yet been stable, therefore the nozzle size (l/min at 3 bar) has not yet been calculated.

The system uses the last saved nozzle size.

3 - Description

Function Diagram for Regulation Valve

ATTENTION! Auto-mode icons are shown, but they could be Manual or Increment Steps icons, depending on driver selection.

Spray job begins

Start condition:

Controller is turned OFF. Pump is turned OFF.

Pressure SmartValve to pressure draining/TurboFiller. Suction

SmartValve to main tank. Water in main tank.

Driver action

Turn the controller ON.

Controller reaction

Controller detects no pressure or flow.

Starts in auto-mode. Sets regulation valve to safe angle to

avoid overpressure at pump start, and to ensure that software

detects, that pump is started (avoiding delay).

Driver action

Turn the pump ON.

Controller action

Controller detects no pressure or flow. Stay in safe position.

Driver action

Turn Pressure SmartValve to Spraying.

Controller reaction

Headland (boom is closed)

Software uses nozzle size and feeds forward

to prepare for opening of boom.

Max. pressure limit is disabled, because last

saved nozzle size is reliable, and therefore the

software “dares” to close the regulation valve

completely.

Headland (boom is closed)

for over 5 minutes

Boom has been closed for a

longer period, so that operator

could have changed to

another nozzle size. Last saved

nozzle size becomes

unreliable.

Software enables maximum

pressure limit.

Controller reaction

Headland (boom is closed)

Controller detects pressure at armature and bypass flow back to tank. Software uses last saved nozzle size and feeds forward

to prepare for opening of the boom.

Max. pressure limit is enabled, because last saved nozzle size

is unreliable, and therefore the software will not close the

regulation valve completely. PrimeFlow booms are primed.

Driver action

Turn Main valve OFF at headland.

Turn Main valve ON to spray.

Driver action

Turn Main valve OFF at headland.

Turn Main valve ON to spray.

Controller reaction

Spraying (boom is open)

Boom is open and sprays.

Both flow measurement and pressure

measurement are good, and the actual

nozzle size is calculated.

The actual nozzle size is used to adjust to

correct volume (liter/hectare).

Flow and pressure are

good

Both flow measurement and

pressure measurement are

good.

Software disables maximum

pressure limit.

Controller reaction

Spraying (boom is open)

Boom is open and sprays.

Software uses last saved nozzle size and pressure sensor to

adjust to correct volume (liter/hectare).

Max. pressure limit is enabled to avoid overpressure. in case

operator has changed to smaller nozzles.

3 - Description

RinseTank

A rinsing tank can be mounted to the rear of the sprayer. The tank is made of impact-proof and chemical resistant polyethylene.

Nominal content is approximately 450 litres.

3 - Description

Filters

An EasyClean suction filter is fitted in the working zone.

A Cyclone pressure filter is fitted to the sprayers right side just in front of the ChemLocker (optional equipment). It has a builtin self-cleaning function.

In-line pressure filters can be fitted at each boom section as an option.

Nozzle filters are fitted at each nozzle.

All filters should always be in use and their function checked regularly. Pay attention to the correct combination of filter and mesh size (see “Spray Technique” book).

EasyClean Filter

To ensure proper function of filter and its built-in valve the filter must be opened at least once every month. A label on the lid also designates this.

• To open filter then turn it counterclockwise and pull it up, like shown on picture.

• Pull out the two locks (A) to remove filter element from the lid.

Besides the spray pressure gauge on the platform an EasyClean clogging indicator is located:

Clogging indicator colour Filter status

Green indicator. No cleaning necessary.

Yellow indicator. It is possible to finish an ongoing spraying job and

then clean the filter after wards.

Red indicator. Clean the EasyClean Filter immediately, as the filter is

clogged.

3 - Description

CycloneFilter

With the CycloneFilter, any impurities in the spray liquid will by-pass the filter and be re-circulated back to the tank via the return flow.

Function diagram

1. Filter lid

2. From pump

3. To boom

4. Return to tank

5. Return valve

The valve (5) has three positions marked with small dots on the lever:

A. This position marked with 1 dot: There is no return flow. Position is

used when rinsing the boom, if there is spray liquid in the main tank. Also used when high spraying volume is required.

B. This position marked with 2 dots: Normal spraying position. With

return flow to prevent filter is going to be clogged when spraying. This position is used when rinsing the boom, if the main tank is empty.

C. This position marked with 3 dots: Flushing position which is used if filter is clogged. Lift and hold the lever to use this

position, which largely increases return flow and flushes the filter. The pressure SmartValve must be set to “Spraying”.

ATTENTION! Use of position C is no guarantee for a clean filter. Always regularly do a visual inspection and cleaning of the filter. If necessary, see “10 Hours Service - CycloneFilter” on page 79.

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DANGER! Never open the Cyclone filter unless the suction valve is closed and the pressure SmartValve is turned to “Main tank”. Otherwise, spraying liquid may hit you, when opening the filter, and thereby draining the main tank!

3 - Description

TurboFiller

Before use

• Pull the handle (A) to unlock.

• Grab the handle to push TurboFiller down (B) until it clicks into

locked down-position.

After use

Pull the handle (A) to unlock.

• Grab the handle to pull TurboFiller back in storing position until it locks.

WARNING! Before releasing the lock (A) always keep a hand on the grip to avoid abrupt movement of the TurboFiller!

TurboFiller Suction Valve

The valve is used simultaneously with the TurboFiller. The valve has 2 settings: Continuously open or spring loaded normally closed. Open the valve when chemicals are to be filled into the TurboFiller and transferred to main tank.

TurboDeflector Valve

This TurboDeflector valve activates the Vortex flushing of the TurboFiller. Lift the lever to lock it in open position for continuous liquid rotation in the hopper.

Chemical Container Rinsing Lever

The upper lever is used for two purposes:

When the TurboFiller lid is open: For rinsing empty containers. Place the container over the rotating flushing nozzle in the middle of the TurboFiller to rinse the inside of the container.

When the TurboFiller lid is closed: Use the Chemical Container Rinsing lever to rinse the hopper when the filling of chemicals is completed.

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DANGER! Do not press the lever unless the multi-hole nozzle is covered by a container as spray liquid may otherwise hit the operator.

Suction from TurboFiller

Start TurboDeflector

Chemical Container Rinsing

3 - Description

Clean Water Tank

A clean water tank is integrated into the right side cover. It is accessed for filling at the sprayers right side when entering the platform. The ball valve is located on the valve cover below the EasyClean filter on sprayers left side. The water in this tank is for hand washing, cleaning of clogged nozzles etc. Only fill this tank with clean water from the well.

Capacity: approximately 20 litres.

WARNING! Although the clean water tank is only filled with clean water, this water must NOT be used for drinking.

DilutionKit (optional)

The dilution kit consist of four valves added to the liquid system, enabling the rinse water to be directed from the rinse tank into the main tank and piping to dilute spray liquid residues.

The dilution kit will ease diluting of chemicals in main tank or boom piping done from the drivers seat while driving in the field. This can be useful when interrupting a spray job, e.g. because of rain or before the tank has to be re-filled at the farm. The dilution kit has two functions that is selected with the optional function switch on the spray controller.

• Tank dilution: Dilute boom piping and the main tank at the same time.

• Boom dilution: Dilute the boom piping only.

NOTE! For cleaning the sprayer, please see “DilutionKit (optional)” on page 24.

NO TE! Dilu tion of che mical res idues may b e req uire d by l aw in cer tai n sit uatio ns be for e re turni ng to the fa rm fo r fill ing or cleaning. Please familiarize with current rules and follow them.

3 - Description

BoomPrime (optional)

BoomPrime is a low pressure circulation system, which primes the spray boom tubes prior to spraying, ensuring a homogenous fluid in the boom tubes and in the main tank. Below the illustration shows the BoomPrime system for the boom. Components are explained in the diagrams for the liquid systems.

•

The BoomPrime system is attached to each end of a boom section (A).

• The boom spray sections are fed into the middle of each section (B).

Liquid for BoomPrime is taken through a bypass valve (D) just before the flowmeter. This valve operates in opposite phase:

When priming, the direction of liquid flow will be reversed. The liquid will be fed into the nozzle tubes from each end, and they will then return any water back to the main tank through the EFC section valves return line (C).

The BoomPrime pressure is adjusted by the handle on the control valve (E), which comprises a pressure gauge.

For adjustment, see “BoomPrime Adjustment (optional)” on page 48.

Operating state Section valves Bypass valve

Spraying Open Closed

Not spraying Closed Open

3 - Description

Diagram - Basic Liquid System

1. Pump

2. EasyClean filter

3. Suction Valve for Tanks

4. Pressure Control Valve

5. Pressure SmartValve

6. CycloneFilter

7. Return Line for Boost Function

8. Bypass Valve for Boom

9. Distribution Valves

10. Pressure Gauge

11. Spray Boom

12. Agitation Valve

13. Agitation Tube

14. Return Line / Riser Pipe

15. One-Way Valve

16. Safety Valve

17. Riser Pipe

18. Purge Valve

3 - Description

Diagram - Liquid System with Options

1. Pump

2. EasyClean Filter

3. Suction Valve for Tanks

4. Pressure Control Valve

5. Pressure SmartValve

6. CycloneFilter

7. Return Line for Boost Function

8. Bypass Valve for Spray Boom

9. Distribution Valves

10. Pressure Gauge

11. Pressure Sensor

12. Spray Boom

13. Agitation Valve

14. Agitation Tube

15. Return Line / Riser Pipe

16. One-Way Valve

17. Safety Valve

18. Riser Pipe

19. Rinsing Nozzles

20. RinseTank

21. RinseTank Coupler

22. Valve Block for TurboFiller

23. TurboFiller

24. Ejector for TurboFiller

25. EcoFill Valve

26. Tank Hose for Turbofiller

27. Filling Coupler

28. Filling Valve

29. FastFiller Ejector

30. FastFiller Hose to Tank Inlet

31. Pressure Empty

32. Pressure Drop Line for Pressure Empty

33. External Cleaning

34. Restrictor

35. Pressure Control Valve

36. EcoFill Coupler

37. Pressure Gauge

38. Dilution Valve (ON/OFF Section Valve)

39. Dilution Valve (S67 Pressure Valve)

40. Dilution Valve (S93 Suction Valve)

41. Dilution Valve for Rinsing

42. One-Way Valve

43. Flowmeter

44. Bypass Valve

45. Purge Valve

3 - Description

Hydraulic Systems

Hydraulic Blocks

Hydraulic blocks fitted to the sprayer are:

Boom

The main boom hydraulic block which manages hydraulic pressure for the boom controls.

ParaLift

This hydraulic block manages hydraulic pressure for the ParaLift.

Open Centre Hydraulics

The open centre hydraulics block is necessary, if the tractor uses open centre hydraulics and/or load sensing. For adjustment, see “Open Centre Hydraulics (optional)” on page 42.

O-LS

3 - Description

AutoHeight UC5

On sprayers with AutoHeight, this hydraulic block manages hydraulic pressure for the automatic boom height control functions.

IntelliTrack Hydraulics (optional)

This IntelliTrack hydraulic block manages hydraulic pressure for the IntelliTrack steering functions.

3 - Description

Boom

Boom and terminology

The FORCE boom (HPZ) is a pendulum suspended, fully hydraulic operated Z-version with all functions controlled via the Direct Hydraulic System (D.H.).

The boom is suspended in a strong, stable parallelogram boom lift. It is available in 24, 27, 28, 30, 32, 33 and 36 m working width. The 24 m to 28 m booms are 2-folded, and the 30 m to 36 m booms are 3-folded.

Boom features:

• Hydraulic pendulum lock.

• Outer sections incorporate spring-loaded breakaway.

• Individual boom tilt control

• Individual folding of outer sections. This enables alternative boom widths.

• The boom can be used in half-folded position. Half-folded lengths are as follows:

For 2-folded booms the terminology are as follows:

A. Breakaway section

C. 1st outer wing

E. Inner wing

F. Centre section

For 3-folded booms the terminology is as follows:

A. Breakaway section

B. 2nd outer wing

C. 1st outer wing

E. Inner wing

F. Centre section

NOTE! When controlling the 3-fold boom via the SetBox, it will fold the 1st and 2nd outer wings in the same step. Folding terminology is as follows:

X. 2nd outer wing

Y. 1st outer wing

Z. Inner wing

Full working width 1/2 folded 2/3 folded

24 metres 12 metres

27 metres 14 metres

28 metres 14 metres

30 metres 12 metres 23 metres

32 metres 14 metres 25 metres

33 metres 14 metres 25 metres

36 metres 14 metres 27 metres

3 - Description

Equipment

ManualTrack

The ManualTrack is used for track correction on slopes, making the sprayer drive a little uphill and follow the track of the rear tractor wheels. The ManualTrack can easily be operated with a toggle switch in the hydraulic control unit.

IntelliTrack

The IntelliTrack will make the sprayer automatically follow the tractors back wheels, when turning on headland. The IntelliTrack can easily be operated with the hydraulic control unit. IntelliTrack has an integrated safety feature which prevents over-steering, when the driving speed is too high for the given turning radius. If a TankGauge is fitted, the tank filling level is also taken into account.

The IntelliTrack is limited to speeds below 18 km/h. Driving in “Auto” with IntelliTrack will trigger an overspeed alarm, and the sprayer will automatically align.

WARNING! During road transport the drawbar must be aligned in centre position and mechanically locked - see “Tracking Drawbar Transport Lock” on page 39. Refer to the Controller instruction book for specific instructions.

NOTE! IntelliTrack requires a controller. More information about the controller can be found in the separate instruction book.

Driving Technique for IntelliTrack

A trailer with IntelliTrack behaves differently than a normal trailer. In tracking position the vehicle centre of gravity is displaced more outwardly compared to the vehicle centre line of a normal trailer. Compared to a conventional trailer, a steered trailer has decreased stability when turning, especially when turning on hillsides (B).

To avoid overbalancing, pay attention to these guidelines:

• Avoid sudden, tight turns.

• Slow down before entering a curve or turning, and drive with a

constant, low speed during the turn.

• Never slow down too fast, never brake heavily and never stop suddenly in a curve, or when turning on a hillside, when the sprayer is articulated.

• Be careful when turning on uneven ground.

• Set the track width (A) as wide as possible.

• The proper function of the hydraulic system is essential to obtain

good stability.

A filled rinsing tank will increase the stability slightly.

3 - Description

Platform

To get access to the platform:

• Pull the step(s) up and swing the step(s) (H) out until it clicking into locked out-position. Retract by pulling up and swing step(s) back to locked in-position.

Components

A. Main tank lid.

B. Pressure gauge and EasyClean clogging indicator.

C. Main tank drain valve.

D. Clean water tank lid.

E. Hand brake.

F. Pressure regulation valve.

G. Agitation valve.

H. Step(s).

Right Side Cover

The right side cover is opened by turning the handle in the lower rear corner of the cover and lifting the cover up.

Main components:

A. Work and road lights box.

B. JobCom box.

C. Clean water tank.

The clean water tank is integrated in the side cover. It is filled from the platform, when the side cover is closed.

ATTENTION! Only open the right side cover, when the clean water tank (optional) is empty!

Tank Level Indicator

The actual tank level in the main tank can be observed on the tank level indicator. The scale is displayed in litres.

ATTENTION! The level indicator is only a guidance for the tank level.

The total deviation of accuracy for the level is 7.5% for a 20% filled tank and below. For above 20% filled tank, the total deviation of accuracy is 5%.

Just behind the main tank scale, a level for the rinsing tank is fitted to the frame. This is a guidance to see if the rinsing tank is full or empty. If the guidance ball is at the top, the rinsing tank is full.

3 - Description

Nozzle Pressure Gauge

The remote pressure gauge is integrated at the top of the platform. This gauge measures the working pressure in the boom tubes as close to the nozzles as possible.

The outputs stated in the nozzle charts are always based on the pressure measured at the nozzle. Both when calibrating and spraying, the pressure must be adjusted according to the readings of this pressure gauge.

ChemLocker (optional)

A ChemLocker for storage of chemical containers etc. is mounted on the sprayers right side.

If the optional FoamMarker is selected, the FoamMarker tank is then placed inside the ChemLocker.

ATTENTION! Maximum load is 100 kg or 100 litres.

SafetyLocker (optional)

The locker is integrated in the front left side, just above the SmartValves.

It is for the purpose of storing non-contaminated protective gear, soap for hand washing etc.

The locker is split in two compartments for the separation of clean clothes from gloves with risk of contamination.

WARNING! Although this locker is meant for storing nontoxic items, it must never be used for storing food, beverage or other things meant for consumption.

3 - Description

Night Spraying Light (optional)

The floodlights (A) are mounted on the boom, and they are positioned to illuminate both boom wings. For wider booms, extra floodlights are mounted in order to further illuminate the outer ends of the boom.

The work light lamp (B) is also mounted to the railing of the platform above the valves. This lamp is positioned to light up the HARDI TurboFiller and the valve system. The boom and work lights are turned on/off in the controller unit in the tractor.

ATTENTION! It is recommended to switch OFF the rear working lights of the tractor in order to save power consumption and to avoid reflection. Power supply is via the 2-pin socket - for more information, see the section for Technical Specifications.

ATTENTION! Turn OFF all work lights and night lights, when driving on public roads!

ATTENTION! If the lights do not function, check the cable connections (see Technical Specifications in this book), and check if the fuses are blown.

Check frequently that the lights are clean. Clean with a dry cloth if needed.

External Cleaning Device (optional)

This equipment comprises a hose reel and a spray gun (C) for cleaning the complete sprayer externally in the field with clean water. The External Cleaning Device is located on the sprayers right side just behind the ChemLocker.

WARNING! The Cleaning Device produces a high pressure and incorrect use may result in personal injuries!

€

DANGER! Never work in bare feet or sandals. It is recommended to wear goggles during the work. It is recommended that the user, or anyone near the cleaning place, protects himself against particles bouncing up during the cleaning.

€

DANGER! For the safety of yourself and others, the following rules should always be observed: Never point the water jet at people, animals, electrical installations or other sensitive objects. Never try to clean clothing or footwear which you or other people wear.

EcoFill (optional)

As an option, an EcoFill coupling can be fitted, which enables the ejector to suck chemicals directly from closed transfer containers.

This kit contains a Parker coupling on the chemical inlet and a Micro Matic coupler to flush the filling hose. Hoses and dosage pumps will be delivered by chemical companies.

24 - 30 m

32 - 36 m

4 - Sprayer setup

General info

Unloading the Sprayer from the Truck

For the unloading of the sprayer, you need a crane. When unloading with a crane please observe the lifting points as shown in the picture, and make sure that the straps or belts used for lifting are strong enough.

ATTENTION! Only lift the sprayer when the tanks are empty!

Pulling the Sprayer at the Tie Down Points

For moving the sprayer or loading it onto e.g. a truck, it can be pulled in the tow hitches or pulling eyes at the rear-end (A), or a hook can be fastened into the hole in the front end of the sprayer (B) as shown.

Before Putting the Sprayer into Operation

Although the sprayer has been supplied with a strong and protective surface treatment on steel parts, bolts etc. in the factory, it is recommended to apply a film of anticorrosion oil (e.g. CASTROL RUSTILO or SHELL ENSIS FLUID) on all metal parts in order to avoid chemicals and fertilizers discolouring the enamel.

If this is done before the sprayer is put into operation for the first time, it will always be easy to clean the sprayer and keep the enamel clean for many years. This treatment should be carried out every time the protection film is washed off.

4 - Sprayer setup

Support Leg

The support leg is stored in the bracket on the sprayer’s right side when the sprayer is attached to the tractor.

To use the support leg

1. Lift the leg off the storage bracket.

2. The support leg can then be mounted to the drawbar extension

on both sides as preferred (high hitch left side only).

3. Secure with the linchpin.

To remove the support leg

1. Lift the leg.

2. Remove the linchpin and pull out the support leg.

3. Secure the leg at the storage bracket with the linchpin.

Jack Up the Sprayer

When the sprayer needs wheel mounting, wheel changing, brake or wheel bearing changing etc. then jack up the sprayer under the axle as shown.

€

DANGER! Be sure to place sprayer at level and firm ground to avoid sprayer falling down from the jack.

ATTENTION! It is good practice to use stop wedges at the opposite wheel!

4 - Sprayer setup

Transmission Shaft

Operator Safety

1. Always STOP THE ENGINE before attaching the transmission shaft to the tractor power take-off (PTO) - most tractor PTO shafts can be rotated by hand to facilitate spline alignment, when the engine is stopped.

2. When attaching the shaft, make sure that the snap lock is FULLY ENGAGED - push and pull the shaft until it locks.

3. Always keep protection guards and chains intact and make sure that it covers all rotating parts, including CV-joints at

each end of the shaft. Do not use without protection guard.

4. Do not touch or stand on the transmis sion s haft, when it is rota ting - keep your safe ty distance at 1.5 me ter. A lso NE VER cross over a rotating PTO shaft to reach the other side of the sprayer.

5. Prevent protection guards from rotating by attaching the chains allowing sufficient slack for turns.

6. Make sure that protection guards around the tractor PTO and the implement shaft are intact.

7. Always STOP THE ENGINE and remove the ignition key, before carrying out maintenance or repairs to the transmission

shaft or implement.

€

DANGER! A ROTATING TRANSMISSION SHAFT WITHOUT PROTECTION GUARDS IS FATAL!

PTO Installation

€

DANGER! As PTO shafts are dangerous in operation, always read the manufacturer’s instruction book before applying any changes to the transmission shaft!

First installation of the transmission shaft is done in the following way:

1. Attach the sprayer to the tractor and set the sprayer height in the position with the shortest distance between the tractor and the sprayer pump PTO shafts.

2. Stop the engine and remove the ignition key.

3. If the transmission shaft needs to be shortened, pull the shaft

apart. Fit the two shaft parts to the tractor and the sprayer pump and measure how much the shaft needs to be shortened. Also mark the protection guards with the same length to be shortened.

WARNING! Only shorten the shaft if it is absolutely necessary!

WARNING! The shaft must always have minimum overlap of half a shaft length!

The recommended overlap (A) of the two shaft parts is 2/3 of the length. The shaft must always have minimum overlap (A) of 1/2 of the length.

4 - Sprayer setup

Mechanical Connections

Drawbars

There is a choice between high and low hitch drawbar versions with different coupling parts. The low version can be configured as a fixed or a steered model. The high hitch has the turning part as standard. The non-steered version has rods instead of cylinders.

All drawbars are fastened to the underside of the sprayer near the rear axle with 6 bolts secured by lock nuts. Furthermore the drawbar is supported by 2 bolts secured with lock nuts located in the area below the platform.

Following drawbar hitches are available - steering or fixed - for both high and low tractor hitch points.

A. Low D33/50 swivel

B. Low D50 hitch

C. Low K80 Zugkugel

D. Low D38 Zugmaul

E. High K80 Zugkugel

F. High D38 Zugmaul

Steering drawbars

4 - Sprayer setup

Fixed drawbars

Fixed Drawbar (High Hitch Extension only)

Make sure the drawbar points straight ahead from its position on the trailer. If not, the two turnbuckles (A) can be adjusted, until the drawbar is centred.

1. Loosen the counternuts (B).

2. Measure the length to be equal for the two turnbuckles (A) to

position the drawbar. Turn the turnbuckles (A), until the measure is correct.

3. Retighten the counternuts (B) again.

Trackin g Drawbar Transport Loc k

The transport lock is a safeguard that will keep the drawbar in a centred position in case of hydraulic leakage during transport on public roads. The transport lock is fixed by swinging the lock plate onto the steering cylinders.

WARNING! Make sure to lock the steering when driving on public roads.

4 - Sprayer setup

Hose Package Support

To prevent hoses and wiring from being damaged by the tractor wheels or the PTO shaft, all hoses, cables and wires are held by the hose package support fitted to the sprayer platform.

ATTENTION! A sprayer with IntelliTrack requires more slack in the cables. Make sure that the hoses and cables are long enough in tight turns, when fully steered.

4 - Sprayer setup

Hydraulic Systems

General Info

Ensure that the snap couplers are clean before connection!

After having operated the boom and the system has been filled with oil, check the tractor’s hydraulic oil level and top up, if necessary.

€

DANGER! Test of the hydraulic system should be done very cautiously. There may be air trapped in the system which can cause violent movements of the boom.

€

DANGER! Hydraulic leaks: Never use your fingers to locate a leakage in any part of the hydraulic system. Due to high pressure, hydraulic oil may penetrate the skin.

Requirements for tractor

The hydraulic system requires:

• One double-acting outlet for the electro-hydraulic operation of the boom functions.

• One double-acting outlet for the operation of the hydraulic pump drive.

• One double-acting outlet for the operation of the hydraulic support leg.

ATTENTION! The hydraulic hoses are marked with arrows to indicate the direction of oil flow.

• The system has a built-in flow regulator that maintains constant speed on hydraulic movements.

• Oil flow between 10 and 90 l/min and a min. pressure of 190 bar.

• Maximum permissible oil pressure is 210 bar.

• Return flow restriction of the connected tractor must be maximum 15 bar.

• For Load Sensing systems, an oil flow of approximately 3 l/min at 25 bar is supplied by the sprayer hydraulics.

4 - Sprayer setup

Open Centre Hydraulics (optional)

The open centre hydraulics block is necessary, if the tractor uses open centre hydraulics and/or load sensing.

The valves (1) and (2) is factory set for open centre hydraulics, but if closed centre hydraulics is used (also in combination with load sensing), screw in the valve (clockwise).

Certain tractor models are able to use Load Sensing without connecting an external sensing line. But if optimal sensing control pressure cannot be obtained, an external sensing line needs to be connected (3). Please consult your tractor dealer for correct setup and correct connection.

WARNING! Before operating the hydraulics, the valve should be set according to the specific tractor model. If you are unsure of the type of hydraulic system in your tractor, please contact your tractor dealer.

Combinations of settings for flow element and circuit value:

*if the tractor requires pressure relief, contact your tractor dealer for further advice.

WARNING! Always be sure to fully open or close the open/closed centre selection valves. Failure to do so may cause damage to vital pump parts.

WARNING! It is essential that connectors on sensing line are kept totally clean. Failure to do so can result in impurities entering the pump and causing damage to vital pump parts.

Valve no. 123 (LS port)

Open centre Out Out Not connected

Closed centre In In Not connected

Load sensing (LS) In Out* Connected

4 - Sprayer setup

Electrical Connections

IntelliTrack Potentiometer Connection

When connecting the IntelliTrack sprayer to the tractor, it is important to set up the front potentiometer on the drawbar correctly. The potentiometer must be connected to the tractor with the supplied 2 chains.

NOTE! To ensure high precision, the chains must be parallel and horizontal.

Procedure when connecting the sprayer to the tractor:

1. Connect the sprayer.

2. Drive forward to ensure the sprayer follows the tractor in a straight

line.

3. Connect the two chains for the potentiometer, while ensuring the transverse potentiometer bar is perpendicular to the drawbar. Tighten the chains, so that the torsion levers (A) are vertical.

4. Go to menu 4.7 in the controller unit and check if the potentiometer reading F is 2.50 Volt, i.e. in the centre position.

5. If the reading F is not correct, adjust the chain connection until F = 2.50 Volt. Allowable deviation is ±0.05 Volt.

Power Supply

Power requirement is 12V DC. Always note polarity! For proper function of the electric equipment, the wires must have the following recommended cross sectional areas and correct fuses to ensure a sufficient power supply. The delivered power connectors follows the standard of most newer tractors. If you have a tractor with another power connector, it is necessary to disassemble the connector and fit it to the actual tractor connector.

The number and the type of connectors may vary on the specific sprayer, depending on its equipment.

Cigar connector Spray control unit requires: Wire 2.5 mm

, Fuse 10 Amp Hydraulic control unit requires: Wire 4.0 mm

, Fuse 16 Amp

7-Pole traffic light connector

JobCom connector The unit requires: Wire 6.0 mm

, Fuse 25 Amp

Working light connector The unit requires: Wire 10.0 mm

, Fuse 30 Amp

4 - Sprayer setup

Installation of Control Unit Brackets

Find a suitable place in the tractor cabin to mount the control units. Best recommended position is to the right of the driver seat.

The supplied tractor pillar bracket (A) has a hole spacing of 100 and 120 mm that fits most tractors. Threaded mounting holes may be hidden behind front corner cover. Check tractor instructions manual for information regarding attachment points.

Three mounting tubes (B) are supplied. One, two or all three may be used. They can be bent and shortened. A spacer (C) is also supplied to allow further attachment possibilities. Find the best solution for your tractor or vehicle.

Tube (B) plate is staggered so that, if correctly orientated, all boxes will line up.

ATTENTION! See also the controllers instruction book for further details of fitting the controller equipment.

Road Safety Kit (optional)

Connect the plug for rear lights to the tractor’s 7-pin socket and check the function of rear lights, stop lights, side lights and direction indicators on both sides before driving.

The wiring is in accordance with ISO 1724. See section in “Technical specifications”.

ATTENTION! Turn OFF all work lights when driving on public roads!

100 -120mm

4 - Sprayer setup

Label for Manually Steered Version (optional)

When having a manually steered sprayer version, there are no hydraulic controls for the steering at the hydraulic control unit. To control the steering, one of the optional switches (10) on the hydraulic control unit is used.

• Place the “Manual steering” label (part no. 72547600) on the control unit at the sign originally meant for optional function (10).

Speed Transducer for Sprayer

The speed transducer and speed ring are located at the inside of the sprayers right wheel. The sensor is an inductive type that requires a metallic protrusion like a speed ring to pass by it to trigger a signal.

Adjustment

1. Assure that the speed ring is correctly fitted to the wheel, so that the arrow (A) follows the forward rotation of the wheel.

2. Adjust so the sensor lines up in the middle of the gaps in vertical direction. Distance from centre of the sensor to top of the brake drum:

• 412 mm brake drum = 60 mm

• 400 mm brake drum = 75 mm

ATTENTION! If necessary, readjust plate on the axle.

3. Adjust air gap (B) to 3 - 6 mm. Use a feeler gauge or similar tool.

NOTE! Adjustment shall be made out of one of the carriage bolts for the speed ring.

4. After adjustment then spin up the wheel. Verify air gap variation less than +/-0.5 mm. Check this at the entire circumference.

5. Verify speed at the controller.

ATTENTION! Correct fitting is indicated by continuous flashing from transducer, when the wheel rotates.

4 - Sprayer setup

Liquid System

CycloneFilter

Standard filter size can be changed by opening the filter top.

Check condition of O-rings and lubricate if necessary or replace if damaged before reassembly.

€

DANGER! Never open the Cyclone filter unless the suction valve is closed and the pressure SmartValve is turned to “Main tank”. Otherwise spraying liquid may hit you, when opening the filter, and drain from the main tank!

4 - Sprayer setup

Label for DilutionKit (optional)

HC 5500

As the dilution kit uses a function switch, the spray control box has to be labelled as shown. The switch in use may differ depending on machine configuration.

ATTENTION! Position of label on the picture is an example only!

HC 6500

1. Press button “F1” to activate “Dilution kit”.

2. Press button “F1” to choose “Dilute boom”.

3. Press button “F2” to choose “Dilute tank”.

When a function is chosen, a timer will automatically start.

4. Press either button “F1” or “F2” to stop the function.

Dist. left DilutionKit

meter

Dist. left DiluteBoom

DiluteTank

Tan k co nt. Ti mer

00:00

meter

litre mm:ss

Dist. left NoDilution

DiluteTank

Tan k co nt. Ti mer

00:09

meter

litre mm:ss

!128

4 - Sprayer setup

BoomPrime Adjustment (optional)

The BoomPrime system works within a fixed pressure range of around 3 bar, but it must be adjusted for the specific spray job (different choice of nozzles etc.):

1. Unfold the boom and start the PTO.

2. Set pressure SmartValve to “Spraying”, suction valve to “Main tank”

and agitation valve to “Agitation”.

3. Adjust the spray pressure to what will be used when spraying.

4. Turn the BoomPrime adjuster screw (A) to increase the BoomPrime

pressure to 3 bar or until the nozzles start to leak.

5. If nozzles leak, then lower the BoomPrime pressure by 1 bar on the adjuster screw (A).

ATTENTION! If not adjusted correctly, nozzles will not close (i.e. will leak) when the spraying is stopped or it will not prime the tubes.

The possible priming circulation speed of BoomPrime relies on the nondrip valves to keep the nozzles closed. If an extended amount circulation may be necessary, the non-drip valves can be changed to a version with higher pressure setting (later opening time).

Non-drip valve Open (bar)

Green (standard) 0.5

Yellow 0.7

4 - Sprayer setup

Track width, axles and wheels

Altering the Track Gauge (optional)

The track gauge of the sprayer can be altered stepless as follows,

Altering procedure

1. Measure the current track width (centre right tyre to centre left tyre). Each side must be extended or retracted half the desired alteration.

2. Attach the sprayer to tractor and engage tractor parking brake.

3. Place stop wedges in front of and behind right wheel. Jack up left

wheel, support and secure sprayer body.

4. Loosen the counternut at the bolts (A) and the bolts (A) for left wheel axle.

5. When having a handbrake, loosen the pointed screw (B) on the brake operating arm.

6. Extend or retract the axle. A sack barrow and a rod will facilitate the operation.

7. Lower down the left wheel.

8. Tighten the clamp bolts (A) to a torque of 250 Nm and lock the

bolts with the counternuts.

9. Repeat the procedure on right wheel.

10. Check if the distance from centre tyre to centre of rear frame is equal at right and left side.

11. Retighten bolts and wheel bolts to specified torque after 8 hours of work.

ATTENTION! The wider the track width, the better the stability of the sprayer. HARDI recommends to work with widest possible track width.

ATTENTION! Depending on configuration of the machine, the track width can be altered in the range from 1800 mm to 2250 mm, in combination of above adjustments and turning of the rims (offset).

Turning the Wheel Rim

Track width can be altered by turning the rims.

After turning the rim around in both sides of the sprayer, the additional track width can be found in the table below.

The rim centre is offset from the wheel hub by 50 mm inwards at delivery.

ATTENTION! When wheels have been mounted or re-tightened, the plastic covers must be mounted on the nuts afterwards.

For 5000 and 6000 litre models, only 10-bolt rims are applicable.

Rim size Fixing bolts New track width

- 8 pcs. 222 mm more

520/85/R42 10 pcs. 226 mm more

650/85/R42 10 pcs. 226 mm more

520/85/R46 10 pcs. 230 mm more

900/50/R42 10 pcs. 230 mm more

4 - Sprayer setup

Counter Weight

To improve stability on articulated models, extra weight can be added by means of liquid-filled tyres. The standard tyre valve is an universal air-water valve. The tyres may be filled with liquid to max. 75% of their total volume.

Use a mixture of water and CaCl

(calcium chloride) to avoid frost

damage as described below:

200 g CaCl

per litre of water gives protection to -15 °C.

300 g CaCl

per litre of water gives protection to -25 °C.

435 g CaCl

per litre of water gives protection to -35 °C.

Filling the tyres

1. Jack up the wheel and rotate wheel till the valve is positioned at “12 o’clock”.

2. Remove the valve body and fill liquid, until it reaches the valve.

3. When surplus liquid is drained through the valve stem, fit the valve

body again.

4. Adjust tyre pressure and lower the wheel. Please refer to “Tyre Pressure” on page 123.

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DANGER! It is very important that the CaCl2 is added to the water and agitated, until it is fully dissolved. Never pour water on to CaCl

! If you get CaCl2 in your eyes, flush instantly with cold water for at least 5 minutes and seek medical

advice afterwards.

WARNING! The tyres must be liquid filled to max. 75 % of total tyre volume. Fill only the quantity. of liquid necessary to obtain sufficient stability of the sprayer. Do not fill liquid and CaCl

mixture in tyres without tubes!

ATTENTION! When filling the tyres, the valve should be positioned at 12 o’clock, and when adjusting the tyre pressure the valve should be positioned at 6 o’clock.

Emptying the tyres

1. Rotate wheel until the valve is positioned at “6 o’clock”.

2. Remove the valve body and lead the liquid away. Retain the liquid

in an appropriate container.

3. To empty the tyre completely, the tyre is inflated and a thin drain tube is led to the bottom of the tyre. The air pressure will now empty the remaining liquid.

4. Remove the drain tube, fit the valve and inflate the tyre to specified pressure. See “Technical Specifications” in the table “Tyre pressure”.

ATTENTION! Disposal of CaCl2 has to take place according to local legislation.

4 - Sprayer setup

Brakes

Emergency and Parking Brake (optional)

The parking brake lever has two function modes, which are determined by the small pawl (A). To change between the two modes, turn the pawl.

Disengage the parking brake

1. Set pawl in position 1.

2. Pull the lever a little forward to release the pawl from the ratchet,

and then push the lever fully backwards.

Engage the parking brake

1. Set pawl control clip in position 2.

2. Pull the lever firmly forwards until parking brake is fully engaged.

Emergency brake

1. Set pawl in position 2.

2. Attach the rope from the hole in top of the hand brake lever to e.g. the tractor top link attaching point (B). If the sprayer

is accidentally unhooked during transport the rope will apply the parking brake before the rope breaks.

ATTENTION! To ensure safe engagement and to avoid damages to the parking brake, use a rope with an ultimate stress between 690 and 785 N.

WARNING! Release the parking brake before driving!

Hydraulically Activated Brakes (optional)

This requires a special trailer brake valve attached to the tractor hydraulic and brake system. Connect the snap coupler to the tractor brake outlet. When the tractor brakes are applied, the trailer brakes will work proportionally to the tractor brakes, and ensure safe and effective braking.

WARNING! Do not connect the brakes directly to the tractor hydraulics without the brake valve. The trailer brake power cannot be controlled, and braking will therefore be hazardous.

WARNING! Maximum oil pressure is 150 bar in the brake line.

Position Rest position Behavior

1 Rest against the pawl Disengage parking brake

2 Point away from the pawl Engage parking brake/Emergency brake

4 - Sprayer setup

Air Activated Brakes (1st option)

This system requires a tractor with air compressor and air brake system with outlet(s) for trailer brakes.

If the air hose(s) are disconnected with air in the brake air tank, control pressure will be dumped and the brakes will engage fully.

If the sprayer e.g. must be moved, the load apportioning valve must be set. Remember to reset the handle to brake position again afterwards.

*If axle load exceeds 5250 kg, position 2 is required to be used.

Air Activated Brakes (2nd option)

Some sprayer sizes are equipped a little differently at delivery, depending on the customer requirements.

*If axle load exceeds 5250 kg, position 3 is required to be used.

ATTENTION! When parking the sprayer, always engage the parking brake, as the air brakes will only be engaged as long as there is air in the tank! Cover the couplings with the dust flaps, when hoses are disconnected.

ATTENTION! The load apportioning valve must be set at the position corresponding to the load on the trailer for obtaining optimal air pressure to the trailer brakes.

WARNING! Driving with a wrong setting for the load apportioning valve will result in excessive or insufficient braking, which can cause hazardous situations.

Manual control of air brakes

The braking system can be controlled manually to move the trailer, when it is not coupled to the tractor.

Near the platform at the front of the trailer, a black and a red operation button are installed in the braking system. Symbols are placed between the buttons (see illustration).

• The two symbols on the left side are for the black button.

Pull this button to engage the service brakes.

Push this button to disengage the service brakes.

• The two symbols on the right side are for the red button.

Pull this button to engage the parking brake.

Push this button to disengage the parking brake.

Posit ion State Use

1 Relieved Move sprayer with air in the tank and without the air hose(s)

connected to the tractor. Disengages the brakes.

2 Full Use when driving with full tank.

3 Half full* Use when driving with tank half full.

4 Empty Use when driving with empty tank.

Posit ion State Use

1 Empty Use when driving with empty tank.

2 Half full* Use when driving with tank half full.

3 Full Use when driving with full tank.

4 - Sprayer setup

Single-Line Air Brakes (optional)

1. Flip the snap coupler protection flap away.

2. Connect the snap coupler to the tractor outlet (black).

3. Let the air compressor fill the sprayer’s air reservoir.

4. Check brake circuit for leaks.

Dual-Line Air Brakes (optional)

1. Flip the snap coupler protection flaps away.

2. Connect the two snap couplers for supply and control to the tractor outlets. The couplers are colour coded and

secured against incorrect attachment:

3. Let the air compressor fill the sprayer’s air reservoir.

4. Check brake circuits for leaks.

Red Supply line (right)

Yellow Control line (left)

4 - Sprayer setup

5 - Operation

General Info

Environmental Info

For environmental info, please refer to the following parts in the Spray Technique Book:

• Nozzles.

• Spray quality.

• Choosing nozzles for arable crops.

• Spraying speed.

5 - Operation

Boom

Safety Info

The boom must not be folded/unfolded while driving! Never use the folding/unfolding functions before the sprayer has been stopped! Failure to do so will damage the boom.

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DANGER! Before unfolding the boom it is important to connect the sprayer to the tractor to prevent overbalancing of the sprayer.

€

DANGER! When folding or unfolding the boom, make sure that no persons or objects are within the operating area of the boom.

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DANGER! Always follow the guidelines listed below when driving in areas with overhead power lines:

Never use the folding/unfolding functions in areas with overhead power lines.

Unintended boom movements may cause contact with overhead power lines.

ATTENTION! A label (ref. no. 978448) follows the sprayer. This label must be placed in the cabin visible from the operator’s seat.

ATTENTION! Only unfold and fold the boom on level ground.

5 - Operation

Manoeuvring of the Boom ( HPZ ) - with HC 6500 / HC 8500 / HC 9500 / ISOBUS

WAR NING!

The pendulum lock automatically turns ON when pressing one of the folding buttons. Boom folding is not

possible, if the pendulum is unlocked. A manual override of the pendulum lock is possible by activating switches 2 or 3.

WARNING! Ensure that transport safety chains are removed and the boom is clear from the transport brackets before unfolding.

WARNING! The folding functions must only be operated when the sprayer is stationary! Failure to do so will damage the boom. The pendulum lock automatically opens at speeds exceeding 1.5 km/h!

ATTENTION! The boom can not be operated with the tractors hydraulic levers.

To unfold th e b o om

WARNING! The pendulum lock automatically opens when you begin to drive. Drive slowly until the pendulum is completely unlocked.

1. Push the lift up button (H) to lift the boom clear of the transport brackets. The symbol appears in display until pendulum is locked. This takes approximately 10 seconds.

2. Push the button (5) to unfold the inner wings completely (approximately 5 seconds or a warning will appear). Check that the pendulum locked symbol is visible in the display.

3. Push the buttons (7) to unfold the 1st outer wings.

4. Push the lift down button (I) to lower the boom to the correct

working height.

5. If not unlocked, then press (2) and symbol appears in display until pendulum is unlocked. This takes approximately 10 seconds.

To fold th e b oom

WARNING! If having SafeTrack is must be aligned and locked before folding.

1. Push slant buttons (E) or (F) to set neutral slant angle (no slant).

2. Push lift up button (H) to raise the boom to the highest possible

position.

3. Push the buttons (6) to fold the 1st outer wings. The symbol appears in display until pendulum is locked. This takes approximately 10 seconds.

4. Push the button (4) to fold the inner wings. Check that the pendulum lock symbol is visible in the display.

5. Push the lift down button (I) to lower the boom until it rests in the paralift locks.

6. Push tilt down buttons (B) and (D) to lower the individual tilt rams until they rest on the front transport brackets.

C D

5 - Operation

Hydraulic Slanting Control (Optional)

The hydraulic boom slanting control enables slanting of the entire boom. This is advantageous when spraying across hillsides.

Reset position to neutral (midway) before folding the boom.

Boom Tilt Function

The following boom tilt function controls enables you to adjust the boom height individually in the right and left hand side.

HC 6500 - HC 8500 - HC 9500 Controller

Boom tilt function controls (A), (B), (C) and (D) on the Grip.

Night Spraying Light (optional)

The night spraying light is turned on in the controller unit in the tractor. Press the A and B buttons.

If traffic light is fitted, the work lights will only work, when the traffic light is on.

5 - Operation

Liquid System

Filling/Washing Location Requirements

When filling the sprayer with chemicals and water, it is important to avoid spot contamination by spraying chemicals in order to protect the subsoil water resources.

A. If the sprayer is always filled on the same location, a special filling/washing location should be established. This should

have a hard, liquid-impenetrable surface (e.g. concrete) securing against seepage, together with edges securing against run-off to the surrounding areas. The location should be drained to an adequate receptacle (e.g. slurry tank or similar).

Any spillage or washings should be retained and diluted in order to be distributed in a larger area. This is to ensure minimal environmental impact and avoid build-up of larger chemical concentrations at one spot.

If no other requirements of distances exist, the following general recommendation of distance can be used. Filling location must be no closer than:

1. 50 metres from public water supplies for drinking purposes, and

2. 25 metres from non-public water supplies for drinking purposes and from treatment sumps and cesspools of

drainage systems, and

3. 50 metres from surface water (watercourses, lakes and coastal waters) and from nature reserves.

D. Alternatively the sprayer can be filled in the field, where the spraying is to take place. If so, choose a different location

for each refilling.

If no other requirements of distances exist, the filling should not take place closer than:

1. 300 metres from public or non-public water supplies for drinking purposes, and

2. 50 metres from surface water (watercourses, lakes and coastal waters), treatment sumps, cesspools of drainage

systems, and nature reserves.

ATTENTION! Legislation and requirements vary from country to country. Always follow local legislation in force at any time.

NOTE! It is the responsibility of the sprayer owner/operator to comply with all relevant legislation. HARDI cannot undertake any responsibilities for incorrect operation and use.

Filling of Water

The tank should normally be filled 1/3 with water before adding chemicals. Always follow the instructions given on the chemical container!

WARNING! If the sprayer is put aside with liquid in the main tank, all manifold valves must be closed.

5 - Operation

Filling Through Tank Lid

Water is filled into the tank by removing the big tank lid, which is located at the top of the sprayer tank near the front, which is accessible from the platform. It is recommended to use as clean water as possible for spraying purposes. Always fill water through the strainer basket to prevent foreign particles from entering the tank. An overhead tank can be used in order to obtain high filling capacity.

WARNING! Do not let the filling hose enter the tank. Keep it outside the tank, pointing towards the filling hole. If the hose is led into the tank, and the water pressure drops at the water supply plant, chemicals may be sucked back and contaminate the water supply lines, supply plant and supply well.

WARNING! The water supply line should be provided with a check valve as additional safety precaution. Follow local legislation in force at any time.

WARNING! The water supply should be provided with a water meter to avoid spillage by over-filling. Follow local legislation in force at any time.

External Filling Device (optional)

The External Filling Device is operated as follows:

1. Remove cover and connect suction hose to Suction Manifold.

2. Turn pressure SmartValve to “Main tank”.

3. Turn handle on External Filling Device valve towards Filling Device.

4. Engage diaphragm pump and set PTO revolutions at 540 rpm.

5. The tank is now filled with water. Keep an eye on the liquid level

indicator.

6. Turn handle on Suction Manifold away from Filling Device to discontinue filling process. Then disengage pump.

7. Disconnect suction hose and replace cover.

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DANGER! Avoid contamination or personal injury. Do not open suction valve towards Suction Filling Device, unless the pump is running and the filling hose is connected. If this valve is opened without the pump running, liquid will stream out of the coupler.

WARNING! Do not leave the sprayer whilst filling the tank, and keep an eye on the level indicator in order NOT to overfill the tank.

WARNING! If suction hose/filter is carried on the sprayer during spraying, it can be contaminated by spray drift which will be transferred to lake/river when filling!

ATTENTION! Observe local legislation regarding use of filling device. In some areas, it is prohibited to fill from open water reservoirs (lakes, rivers etc.). It is strongly recommended only to fill from closed reservoirs (mobile water tanks etc.) to avoid contamination.

5 - Operation

Filling of Rinsing Tank (optional)

The rinsing tank is filled via the 1” threaded connection piece at the valve system:

1. Remove the filler cap, then fit the external water hose to the threaded connection piece.

2. Engage external water pump, if any.

3. Keep an eye on the level indicator in order not to overfill the tank.

4. Stop filling and refit the cap.

Volume: approximately 450 litres.

ATTENTION! Only fill rinsing tank with clean water! To avoid algae developing in the rinsing tank, always drain this tank, if the sprayer is not in use for a longer period of time.

ATTENTION! For cleaning purposes etc. the rinsing tank is also accessible via the tank lid on top of the tank.

Filling of Clean Water Tank

To fill the clean water tank:

1. Remove the tank lid

2. Fill with clean water

3. Reposition the tank lid.

For use of water:

• Turn the ball valve lever to open. The ball valve is located on the valve cover.

The water from this tank is for hand washing, cleaning of clogged nozzles etc.

ATTENTION! Only fill this tank with clean water! To avoid algae developing in the clean water tank, always drain this tank, if the sprayer is not in use for a longer period of time.

WARNING! Although the clean water tank is only filled with clean water, this water must NOT be used for drinking.

5 - Operation

Safety Precautions - Crop Protection Chemicals

Always be careful when working with crop protection chemicals!

WARNING! Always wear proper protective clothing before handling chemicals!

Personal protection

Depending on chemical type, protective gear/equipment should be worn to avoid contact with the chemicals, such as:

• Gloves

• Waterproof boots

• Headgear

• Respirator

• Safety goggles

• Coverall with chemical resistance

WARNING! Protective clothing/equipment should be used, when preparing the spray liquid, during the spray job and when cleaning the sprayer. Follow the chemical manufacturer’s instructions given on the chemical label and/or local legislation.

WARNING! It is always advisable to have clean water available, especially when filling the sprayer with chemicals.

WARNING! Always clean the sprayer carefully and immediately after use.

WARNING! Only mix chemicals in the tank according to directions given by the chemical manufacturer.

WARNING! Always clean the sprayer before changing to another chemical.

Filling Chemicals through Tank Lid

The chemicals are filled through the tank lid - Note instructions on the chemical container!

WARNING! Be careful not to slip or to splash chemicals, when carrying chemicals up to the tank lid!

ATTENTION! Due to risk of spillage and spot contamination, several countries do not allow to fill chemicals directly through the tank lid. Use the TurboFiller for all filling of chemicals instead.

1. Make sure the spray control unit is switched off.

2. Set suction valve towards “Suction from main tank”, Agitation valve

towards “Agitation”. Turn pressure SmartValve towards “Spraying”.

3. Engage the pump and set PTO revolutions to 540 rpm.

4. Add the chemicals through the main tank hole.

5. Keep PTO engaged, so that the spray liquid is continuously

agitated, until it has been sprayed on the crop.

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DANGER! Before turning Pressure SmartValve past “Pressure draining/TurboFiller”, it is very important to ensure that the quick coupler lid is correctly and completely mounted to the filling stud in its locked position. Failure to do so causes a risk of contamination and injury from the quick coupler lid being “shot” off when pressurized! If it is not possible to mount the lid completely, lubricate the rubber seal and the grip hooks.

NOTE! Local legislation may not allow filling through the tank lid, but will require use of the chemical inductor instead.

5 - Operation

Filling Liquid Chemicals by using HARDI TurboFiller

NOTE! We advice to use the TurboFiller, when you fill chemicals from an external tank.

1. Fill the main tank at least 1/3 with water (unless otherwise stated on the chemical container label).

2. Turn the handle of the suction valve towards “suction from Main tank”. Turn pressure SmartValve towards “Pressure draining/TurboFiller”. Close the AgitationValve.

NOTE! If filling water from an external tank, this can be continued while doing the next steps.

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DANGER! Before turning Pressure SmartValve to “Pressure draining/TurboFiller” it is very important to be sure that the quick coupler lid is correct and completely mounted to the filling stud into its locked position. Failure to do so may cause risk of contamination and injury from quick coupler lid being “shot” off when pressurized! If not possible to mount lid completely, lubricate the rubber seal and the grip hooks.

3. Engage the pump and set PTO speed at 540 rpm or 1000 rpm (depending on pump model).

4. Open TurboFiller lid. Measure the correct quantity of chemical and fill it into the hopper.

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DANGER! Always wear face shield and other appropriate personal safety equipment, when filling chemicals.

ATTENTION! The scale in the hopper can only be used, if the sprayer is parked on level ground! It is recommended to use a measuring jug for best accuracy.

5. Engage the hopper transfer device by opening the TurboFiller suction valve to transfer chemicals to the main tank. The TurboFiller suction valve must be open for at least 20 seconds after the chemical is no longer visible in the hopper, in order to empty the transfer hoses completely into the main tank.

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DANGER! If the TurboFiller and the transfer hoses are not completely emptied, there is a risk of chemicals being sucked out of the main tank!

6. If the chemical container is empty, it can be rinsed by the Chemical Container Cleaning device. Place the container over the multi-hole nozzle and push the container for cleaning.

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DANGER! In order to avoid spray liquid hitting the operator, do not press the lever, unless the multi-hole nozzle is covered by a container, as spray liquid may otherwise hit the operator!

ATTENTION! The rinsing device uses spray liquid to rinse containers for concentrated chemicals. Before disposal, always rinse the chemical containers with clean water several times, until they are clean.

7. Flush the TurboFiller with clean water from the rinsing tank. The TurboFiller suction valve must be open for at least 20 seconds after the rinse water is no longer visible in the hopper, in order to empty the transfer hoses completely into the main tank.

ATTENTION! If not flushed with clean water, the hopper rinsing device uses spray liquid for rinsing the hopper! Cleaning the TurboFiller must always be done, when the spray job is ended, and together with cleaning the entire sprayer. A cleaning after the last filling, and before spraying, does not ensure a clean TurboFiller!

8. Close the TurboFiller suction valve, when the hopper has been rinsed. Close the lid.

9. Turn the AgitationValve towards “Agitation”.

5 - Operation

10. When the spray liquid is well agitated, turn handle of the pressure SmartValve towards “Spraying” position. Keep PTO engaged, so that the spray liquid is continuously agitated, until it has been sprayed on the crop.

Filling Powder Chemicals by using HARDI TurboFiller

1. Fill the main tank at least 1/2 with water (unless otherwise stated on the chemical container label). See section “Filling of water”.

2. Turn the handle of the suction valve towards “suction from Main tank”. Turn pressure SmartValve towards “Pressure draining/TurboFiller”. Turn the AgitationValve towards “Agitation” if required. Close remaining valves.

ATTENTION! For increased suction from the TurboFiller the AgitationValve can be kept closed.

NOTE! If filling water from an external tank, this can be continued while doing the next steps.

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DANGER! Before turning Pressure SmartValve to “Pressure draining/TurboFiller” it is very important to be sure that the quick coupler lid is correct and completely mounted to the filling stud into its locked position. Failure to do so may cause risk of contamination and injury from the quick coupler lid being “shot” off when pressurized! If not possible to mount lid completely, lubricate the rubber seal and the grip hooks.

3. Engage the pump and set PTO speed at 540 rpm or 1000 rpm (depending on pump model).

4. Open TurboFiller lid. Open TurboDeflector valve and TurboFiller suction valve.

5. Measure the correct amount of powdered chemical and sprinkle it into the hopper as fast as the transfer device can

flush it down. The TurboFiller suction valve must be open for at least 20 seconds after the chemical is no longer visible in the hopper in order to completely empty the transfer hoses into the main tank.

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DANGER! If the TurboFiller and the transfer hoses are not completely emptied, there is a risk of chemicals being sucked out of the main tank!

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DANGER! Always wear face shield and other appropriate personal safety equipment, when filling chemicals.

6. If the chemical container is empty, it can be rinsed by the Chemical Container Cleaning device. Place the container over the multi-hole nozzle and push the upper lever to the left of the TurboFiller.

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DANGER! In order to avoid spray liquid hitting the operator, do not press lever unless the multi-hole nozzle is covered by a container, as spray liquid may otherwise hit the operator!

ATTENTION! The rinsing device uses spray liquid to rinse containers for concentrated chemicals. Always rinse the chemical containers with clean water several times, until they are clean before disposal.

7. Flush the TurboFiller with clean water from the Rinsing tank. The TurboFiller suction valve must be open for at least 20 seconds after the rinse water is no longer visible in the hopper, in order to completely empty the transfer hoses into the main tank.

5 - Operation

8. Close TurboFiller suction valve, when the hopper has been rinsed. Close the lid.

9. If closed, turn the AgitationValve towards “Agitation”.

10. When the spray liquid is well agitated, turn handle of the pressure

SmartValve towards “Spraying” position. Keep PTO engaged, so that the spray liquid is continuously agitated, until it has been sprayed on the crop.

Agitation before Resuming a Spray Job

If a spray job has been interrupted for a while, severe sedimentation may occur depending on the chemicals being used. Before resuming the spray job, it might be necessary to agitate sediment material.

1. Turn the handle at the suction valve towards “Suction from main tank”. Turn the pressure alve towards “Pressure draining/TurboFiller” and turn the Agitation valve towards “Agitation”. Other valves closed.

2. Engage the pump and set PTO speed to 540 rpm or 1000 rpm (depending on pump model).

3. Agitation has started and should be continued for at least 10 minutes.

4. The spray job can now be resumed. Turn pressure SmartValve towards “Spraying” and start spraying.

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Parking the Sprayer

To avoid spot contamination, the sprayer should always be parked at either the washing/filling location or under roof.

This prevents rainfall from washing down chemical residues from the sprayer's surfaces.

• Parking at the washing/filling location will retain residues.

• Always park the machine out of reach of children, animals and unauthorized persons.

5 - Operation

EcoFill (optional)

The optional EcoFill is an extra valve situated between the EasyClean filter and the TurboFiller. A Parker coupling is fitted to the EcoFill valve and a Micromatic coupling is situated just below the EasyClean filter.

Use the EcoFill valve to select whether chemical transfer is done via the TurboFiller or by suction directly from the chemical container.

Procedure when filling from a container with EcoFill:

1. Connect the suction hose to the Parker coupling and the other end of filling hose to the chemical container with the Micromatic coupler.

2. Turn pressure SmartValve to “Pressure draining/TurboFiller”. Turn Suction Valve to “Main tank”.

3. Turn the EcoFill valve to “Suction from external container”.

4. Lift the TurboFiller suction valve to open position on the TurboFiller to enable the vacuum.

5. Engage the pump and set PTO speed to 540 rpm or 1000 rpm (depending on pump model).

6. When the chemical container is empty, then the hose can be rinsed by moving the Micromatic connector from the

chemical container to the Micromatic coupler on the sprayer.

7. Then turn the suction SmartValve to “Suction from rinsing tank”.

8. Engage the pump and set PTO speed at 540 rpm or 1000 rpm (depending on pump model) to flush the hose.

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DANGER! Before turning Pressure SmartValve to “Pressure draining/TurboFiller”, it is very important to ensure that the quick coupler lid is correctly and completely mounted to the filling stud in its locked position. Failure to do so causes a risk of contamination and injury from the quick coupler lid being “shot” off when pressurized! If it is not possible to mount the lid completely, lubricate the rubber seal and the grip hooks.

5 - Operation

TurboFiller Rinsing

NOTE! It is important to suck from the rising tank or an external tank with clean water.

Rinse the TurboFiller and chemical containers as follows:

Cleaning empty containers - TurboFiller lid is open

1. Put container over the rotating flushing nozzle in the middle of the TurboFiller, so that the nozzle is inside the container.

2. Simultaneously press the Chemical Container Cleaning lever and the TurboFiller suction valve. This rinses the chemical container with the flushing nozzle, while the rinsing liquid is emptied out of the TurboFiller.

TurboFiller rinsing - TurboFiller lid is closed

1. Close TurboFiller lid.

2. Turn the suction SmartValve towards “Rinsing tank” or “External Filling Device”, if clean water is available here.

3. Open the Turbo Deflector Valve for 1 minute to get plenty of clean water through the hoses.

4. Simultaneously press the Chemical Container Cleaning lever and the TurboFiller suction valve. This rinses the hopper

with the flushing nozzle, while the rinsing liquid is emptied out of the TurboFiller.

5. Rinse the hopper for 30-40 seconds.

6. Open the lid to inspect if the TurboFiller is empty. If not, close the lid again and press the TurboFiller suction valve, until

the TurboFiller is empty.

7. After the last flushing, the TurboFiller suction valve must be open for at least 20 seconds, after the rinse water is no longer visible in the hopper, in order to completely empty the transfer hoses into the main tank.

ATTENTION! The TurboFiller needs to be cleaned thoroughly after finishing spraying. This is to ensure that it is clean, before spraying other crops that may be sensitive to the chemicals just used. See section “Cleaning” on page 69 for details.

BoomPrime (optional)

The BoomPrime system works automatically, and it is activated, when a spray job is prepared:

1. Unfold the boom and turn on the PTO.

2. Set pressure SmartValve to “Spraying”, suction valve to “Main tank”

and agitation valve to “Agitation”, if needed.

3. Adjust the spray pressure to what will be used when spraying.

4. The boom will then be fully primed within 1-2 minutes.

If the nozzles start to leak, when closing one or more sections during a spray job, proceed as follows:

1. Adjust the pressure on the BoomPrime pressure regulation.

2. Turn Pressure SmartValve to “Main tank”.

3. Disconnect the PTO.

If adjustment of the BoomPrime system might be necessary, please refer to “BoomPrime Adjustment (optional)” on page 48.

5 - Operation

DilutionKit (optional)

See “DilutionKit (optional)” on page 68 for explanation of tank and boom dilution.

Tan k dilut ion

When the main tank is empty then dilute residual spray liquid before returning to the farm for refilling.

1. Turn off the Main valve On/Off.

2. Select “Tank dilution” (A).

3. Fill approximately 150 litres (1/3 tank) from the rinsing tank into the

main tank.

4. Select “Spraying” (B) for at least 30 seconds.

5. Turn on the Main valve On/Off. Resume driving in the field to spray out the diluted spray liquid.

6. While spraying the diluted liquid, then turn off the Main valve On/Off for a short while, and then turn it on again. This

also dilutes the pressure equalization piping.

7. Repeat step 1-6 twice (until the rinsing tank is empty).

Boom dilution

When a spray job is interrupted, then chemical residues in the boom piping must be diluted, before returning to the farm.

1. Continue driving in the field with the Main valve On/Off open.

2. Select “Boom dilution” (C).

3. Dilute boom piping by spraying approximately 200 litres (1/2 tank)

from the rinsing tank on the field.

4. Turn off the PTO to stop dilution of the boom piping.

5. Select “Spraying” (B) to be ready to resume spraying later.

6. Turn off Main valve On/Off and drive home.

NOTE! Do not turn off the Main valve On/Off, while diluting the boom piping. This will dilute the remaining spray liquid in the main tank!

5 - Operation

Cleaning

General Info

In order to derive full benefit from the sprayer for many years ,the following service and maintenance program should be followed.

ATTENTION! Always read the individual paragraphs. Read instructions for service/maintenance jobs carefully before starting on the job. If any portion remains unclear, or if it requires facilities which are not available, then please leave the job to your HARDI dealer’s workshop for safety reasons.

ATTENTION!

Clean sprayers are safe sprayers.

Clean sprayers are ready for action.

Clean sprayers cannot be damaged by pesticides and their solvents.

Guidelines

• Read the whole chemical label. Take note of any particular instructions regarding recommended protective clothing, deactivating agents, etc. Read the detergent and deactivating agent labels. If cleaning procedures are given, follow them closely.

• Be familiar with local legislation regarding disposal of pesticides washings, mandatory decontamination methods, etc. Contact the appropriate authority if you are in doubt.

• Pesticide washings can usually be sprayed out on the field just sprayed or at a suitable cultivated area. Avoid emptying the washings at the same spot every time and keep sufficient distance to the water environment. You must prevent seepage or runoff of residue into streams, watercourses, ditches, wells, springs, etc. The washings from the cleaning area must not enter sewers. Alternatively the washings can be retained in an appropriate receptacle, diluted and distributed over a larger cultivated area - see also “Filling/Washing Location Requirements” on page 59.

• Cleaning starts with the calibration, as a well calibrated sprayer will ensure the minimal amount of remaining spray liquid.

• It is good practice to clean the sprayer immediately after use, and thereby rendering the sprayer safe and ready for the next pesticide application. This also prolongs the life of the components. It is strongly advised to perform an internal cleaning of the sprayer, when high concentrations of acids or chloride are present in the active ingredients, or if the spray liquid is corrosive. For the best result, use a cleaning agent recommended by HARDI, e.g. AllClearExtra.

• It is sometimes necessary to leave spray liquid in the tank for short periods, e.g. overnight, or until the weather becomes suitable for spraying again. Unauthorized persons, children and animals must not have access to the sprayer under these circumstances.

• If the product applied is corrosive, it is recommended to coat all metal parts of the sprayer before and after use with a suitable rust inhibitor.

• The sprayer must always be parked under roof to avoid rain washing off pesticides as well as build-up of spot contamination in the soil. If parked outside, the sprayer should be parked on the filling/washing location in order to retain possible pesticides.

5 - Operation

Quick Reference - Cleaning

NOTE! Pump speed 250-280 rpm.

A. Turn On.

B. Turn Off.

C. Minimum 45 seconds with nozzle Off.

D. Spray until air comes out of nozzles. When pressure drops, close regulation valve by pressing the button, until

yellow LED lights on the valve. When the boom is completely empty, press the button for a few seconds to avoid pressure spike.

Standard Cleaning

ATTENTION! For cleaning between spray jobs where crops are not very sensitive towards chemicals just sprayed.

1. Engage pump with tractor in idle, so that pump speed is as low as possible (250/550 rpm, depending on pump type).

2. Turn suction valve towards and the pressure SmartValve towards while sucking approximately 1/6 of the

rinse tank content into the main tank. It is important to have full agitation for approximately 20 seconds, and then close agitation valve completely.

3. Turn suction valve towards and the pressure SmartValve towards with all sections off for approximately 45 seconds.

4. Turn all sections on. Spray until air comes out of nozzles. When pressure drops, close regulation valve by pressing the

button, until yellow LED lights on the valve. When the boom is completely empty, press the button for a few

seconds to avoid pressure spike.

Repeat the following 3 steps 5 times:

1. Turn suction valve towards and the pressure SmartValve towards while sucking approximately 1/6 of the rinse tank content into the Main tank.

2. Turn suction valve towards and the pressure SmartValve towards with all sections off for approximately 45 seconds.

3. Turn all sections on. Spray until air comes out of nozzles. When pressure drops, close regulation valve by pressing the

button, until yellow LED lights on the valve. When the boom is completely empty, press the button for a few

seconds to avoid pressure spike.

5 x 1/65 x 1/6

1/61/6

A B C

5 - Operation

Cleaning the Tank and Liquid System

ATTENTION! Thorough cleaning of the sprayer is to be carried out when shifting to crops, which are very sensitive to chemicals just sprayed, or prior to storage for a longer period of time.

NOTE! Prior to the described cleaning, a standard cleaning should be carried out.

• Select and use the appropriate protective clothing. Select detergent suitable for cleaning and suitable deactivating agents if necessary.

• Rinse and clean sprayer and tractor externally. Use detergent if necessary.

1. Remove tank filters and suction filters and clean the sprayer. Be careful not to damage the filter mesh. Put back the

suction filter top. Put back all filters, when the sprayer is completely clean.

2. With the pump running, rinse the inside of the tank. Do not forget to clean the tank roof. Rinse and operate all components and any equipment, which have been in contact with the chemical. Before opening the distribution valves and spraying the liquid out, decide whether this should be done in the field or on the seepage location.

3. After spraying the liquid out, stop the pump and fill at least 1/5 of the tank with clean water. Note that some chemicals require the tank to be completely filled. Add appropriate detergent and/or deactivating agent, e.g. washing soda or triple effect ammonia. Special detergents for sprayer cleaning is recommended as some also lubricate ball valves etc.

4. Start the pump and operate all controls enabling the liquid to come into contact with all the components. Operate the distribution valves as the last thing. Some detergents and deactivating agents work best, if they are left in the tank for a short period. Check the label.

5. Drain the tank and let the pump run dry. Rinse inside of the tank, again letting the pump run dry.

6. Stop the pump. If the pesticides used have a tendency to block nozzles and filters, remove and clean them

immediately.

7. Put back all the filters and nozzles and store the sprayer. If it is noted, from previous experiences, that the solvents in the pesticides are particularly aggressive, store the sprayer with the tank lid open.

ATTENTION! It is advisable to increase the forward speed (double, if possible) and reduce the spraying pressure to 1.5 bar, when spraying diluted remaining liquid in the field just sprayed.

ATTENTION! If a cleaning procedure is given on the chemical label, follow it closely.

ATTENTION! If the sprayer is cleaned with a high pressure washer, lubrication of the entire machine is recommended.

Cleaning and Maintenance of Filters

Clean filters ensure:

• Sprayer components such as valves, diaphragms and operating units are not hindered or damaged during operation.

• Nozzle blockades do not occur whilst spraying.

• Long life of the pump. A blocked suction filter will result in pump cavitation. The main filter protecting sprayer

components is the suction filter. Check it regularly.

5 - Operation

Use of Rinsing Tank and Rinsing Nozzles (Optional)

The incorporated rinsing tank can be used for two different purposes.

ATTENTION! If a cleaning procedure is given on the chemical label, follow it closely.

In-field diluting before cleaning

In-field diluting of remaining spray liquid residue in the spraying circuit should be carried out, before cleaning the sprayer.

Rinsing the main tank and liquid system:

1. Empty the sprayer as much as possible. Close the AgitationValve (no agitation) and spray until air comes out of all nozzles.

2. Turn suction valve towards and pressure SmartValve towards .

3. Engage and set the pump speed to approximately 300 rpm.

4. When 1/3 of the contents in the rinsing tank is used, turn suction valve towards and operate all valves on the

pressure side of the system in the following order, so that all hoses and components are rinsed:

A. Turn the pressure SmartValve towards to activate the ejector and open the TurboFiller suction valve.

B. Open the TurboDeflector valve and close it again, when clean water comes out of nozzles.

C. Close the TurboFiller lid. and squeeze the Chemical Container Cleaning grip to clean this device.

D. Open the TurboFiller lid again, and make sure that the TurboFiller is empty.

E. When empty, close the TurboFiller suction valve again. Take care that the External fast filling connection and the

line are not contaminated with chemicals.

5. Turn the suction valve towards and the pressure SmartValve towards , and spray the liquid in the field just sprayed.

Cleaning of Main Tank:

6. Turn the suction valve towards and the pressure SmartValve towards . Remove the filling strainer to avoid any cleaning shadows behind it.

7. When another 1/6 of the contents in the rinsing tank is used, turn the suction valve towards .

8. Turn pressure SmartValve towards , and spray the liquid in the field just sprayed.

9. Repeat step 6 - 8 one more time.

WARNING! When critical chemicals (like sulphonylurea) have been used, or a cleaning detergent is recommended, do an extra cleaning:

10. Fill the rinse tank again.

11. Fill the main tank with 500 litres of clean water. See section “External Filling Device” for filling procedure.

12. Add the cleaning detergent to the main tank by using the TurboFiller. Follow instructions on the label of the cleaning

agent.

13. Clean the whole system again.

14. To get the best cleaning effect, the Self-Cleaning Filter and the Suction Filter sieves should be washed with clean water.

15. Rinse the sprayer with clean water afterwards.

ATTENTION! The rinsing nozzles cannot always guarantee a 100% cleaning of the tank. Always clean manually with a brush afterwards, especially if crops, which are sensitive to the chemical just sprayed, are to be sprayed afterwards!

5 - Operation

Rinsing when main tank is not empty

Rin sing t he pu mp, opera ting u nits , spr ay li nes, etc. in ca se of stop in spr aying (e. g. b ecaus e of r ain), befo re m ain ta nk is empty.

Cleaning of the liquid system:

1. Turn suction valve towards . (Keep pressure SmartValve in -position).

2. Close AgitationValve (no agitation).

3. Engage the pump and spray the water from the rinsing tank into the field, until all nozzle tubes and nozzles have been

flushed with clean water.

4. Disengage pump again.

ATTENTION! It is advisable to increase the forward speed (double, if possible) and reduce the spraying pressure to 1.5 bar, when spraying diluted remaining liquid in the field just sprayed.

Cleaning the sprayer on the outside

1. Turn suction valve towards and pressure SmartValve towards .

2. When another 1/3 of the contents in the rinsing tank is used, turn the suction valve towards .

3. Turn pressure Agitation valve towards and wash the sprayer with the cleaning device located on sprayer’s right

side.

4. Disengage pump again.

ATTENTION! If the sprayer is cleaned with a high pressure washer, lubrication of the entire machine is recommended.

Technical Residue

An amount of spray liquid will inevitably remain in the system. It cannot be sprayed properly on the crop, as the pump takes in air, when the tank is just about empty.

This technical residue is defined as the remaining amount of liquid in the system, when the first clear pressure drop appears on the pressure gauge. The residual dilutable volume is 41 litres. See “Technical Residue” on page 122 for specific technical residues.

The residues in the tank should be diluted immediately in a ratio of 1:10 with clean water. Afterwards it should be sprayed on the crop just sprayed with increased driving speed. In addition, also pump, linkage and armature can be separately rinsed with water from the rinsing tank. However, it must be ensured that the liquid in the spray lines are in unchanged concentration. Therefore there should be an untreated field area available to spray this liquid out.

Using the Drain Valve

The drain valve is operated from the platform just beside the main tank lid.

1. Pull the string to open the drain valve.

2. The valve is spring-loaded, but can be kept open by pulling the

string upwards in the V-shaped slit.

3. To release, pull the string downward and the valve will close automatically.

If draining residues, e.g. liquid fertilizer into a reservoir, a snap coupler with hose can rapidly be connected to the drain valve, and the liquid is safely drained.

5 - Operation

Pressure Draining (optional)

It is possible to drain to an external tank. This is done the following way:

1. Connect a hose from an external tank to the pressure quick coupler on the sprayer.

2. Turn the Pressure SmartValve towards .

3. Turn the suction valve towards .

4. Engage the PTO to start the pump.

5. When the tank is drained, then turn off the PTO again.

6. Disconnect the hose and put back the quick coupler lid.

€

DANGER! Before turning Pressure SmartValve to , it is very important to ensure that the quick coupler lid is correctly and completely mounted to the filling stud in its locked position. Failure to do so causes a risk of contamination and injury from the quick coupler lid being “shot” off when pressurized! If it is not possible to mount the lid completely, lubricate the rubber seal and the grip hooks.

Outside Cleaning - Use of External Cleaning Device (optional)

Use the External Cleaning Device to wash everything on the outside of the sprayer.

1. Unroll the hose from the reel.

2. Engage pump speed to approximately 250 rpm or 560 rpm,

depending on pump model.

3. Turn suction SmartValve towards and pressure SmartValve towards or not used function.

4. Turn agitation valve towards and clean the sprayer.

5. After cleaning, close the agitation valve again.

6. Roll the hose to the reel again.

€

DANGER! Before turning Pressure SmartValve to , it is very important to ensure that the quick coupler lid is correctly and completely mounted to the filling stud in its locked position. Failure to do so causes a risk of contamination and injury from quick coupler lid being “shot” off when pressurized! If it is not possible to mount lid completely, lubricate the rubber seal and the grip hooks.

ATTENTION! If the safety valve is activated, then lower the PTO speed to minimize the amount of rinsing water being lost into the main tank.

ATTENTION! If the sprayer is cleaned with a high pressure washer, lubrication of the entire machine is recommended.

• Spray Technique - see separate book.

• Optional Extras - see separate books.

6 - Maintenance

Lubrication

General Info

Always store lubricants clean, dry and cool - preferably at a constant temperature - to avoid contamination from dirt and condensed water. Keep oil filling jugs, hoppers and grease guns clean, and clean the lubricating points thoroughly before lubricating. Avoid skin contact with oil products for longer periods.

Always follow the quantity recommendations. If no quantity is recommended, feed the lubricator until new grease becomes visible.

Pictograms in lubrication & oiling plans designate the following:

1. Lubricant to be used (see “Recommended lubricants”).

2. Recommended intervals (hours).

ATTENTION! If the sprayer is cleaned with a high pressure washer, lubrication of the entire machine is recommended.

Recommended Lubricants

BALL BEARINGS: Universal Lithium grease, NLGI No. 2 SHELL RETINAX EP2 CASTROL LMX GREASE

SLIDE BEARINGS: Lithium grease with Molybdenumdisulphide or graphite SHELL RETINAX HD 2 (or HDX 2)

OIL LUB. POINTS: TOTAL Transmission TM SAE 80W/90 Castrol EPX 80W/90 SHELL Spirax 80W/90 Mobil Mobilube 80W/90

6 - Maintenance

Boom lubrication & oiling plan

6 - Maintenance

Trailer/ParaLift Lubrication & Oiling Plan

Central lubrication

PTO Lubrication & Oiling Plan

PTO shaft, type 100 series

C-50

6 - Maintenance

Service and Maintenance Intervals

10 Hours Service - EasyClean Filter

This filter has a clogging indicator as mentioned in the “Description” chapter, but even if this indicator does not show clogging, the filter mostly needs cleaning every 10 hours.

Servicing the filter

1. Turn the filter lid counterclockwise to open it.

2. Remove lid and filter from the filter housing.

3. Separate filter element from lid/filter guide by turning locks

outwards.

4. Clean filter and if necessary clean the housing for larger impurities.

To reassem b l e

1. Grease the O-ring on the filter lid.

2. Press the filter onto the filter guide/lid. Make sure that it has caught

the guide.

3. Reassemble filter/filter lid into the housing. Make sure that it has caught the guide in the bottom of the housing.

4. Turn the filter lid clockwise to close it.

WAR NING! Al ways we ar protective clothing and gloves before servicing the filter!

6 - Maintenance

10 Hours Service - CycloneFilter

Servicing the filter

1. Turn the pressure valve towards the unused function or to tank cleaning nozzles.

2. Unscrew the filter lid (A).

3. Lift lid and filter (B) from the housing.

4. Turn the two locks (C) outwards to unlock the filter from the lid.

5. Separate filter from the integrated filter guide in the lid and clean

the filter.

To reassem b l e

1. Grease the two O-rings on the lid/filter guide. Due to small space at lid, use for example a brush to apply the grease.

2. Mount the filter onto the recess (which may not be greased) in the lid/filter guide.

3. Turn the two locks (C) inwards to lock the filter to the lid.

4. Place the filter/filter lid into the housing and screw the lid, until it hits the stop.

WARNING! Always wear protective clothing and gloves, before servicing the filter!

€

DANGER! The pressure valve must always be turned to the unused function or to tank cleaning nozzles, before opening the CycloneFilter! If not, the spraying liquid can hit you, when opening the filter, and the main tank content will drain away!

10 Hours Service - In-Line Filter (optional)

If the boom is equipped with In-Line Filters, unscrew the filter bowl to inspect and clean the filter. When reassembling, the O-ring should be greased.

Alternative filter meshes are available. See section on Technical specifications - Filters and nozzles.

WARNING! Be careful not to splash out liquid, when unscrewing the filter bowl.

WARNING! Always wear protective clothing and gloves, before servicing the filter!

10 Hours Service - Nozzle Filters

The filters are located inside the nozzles. Check and clean.

6 - Maintenance

10 Hours Service - Spraying Circuit

Fill with clean water and operate all functions. Check for leaks using a higher spray pressure than normal. Check nozzle spray patterns visually using clean water.

10 Hours Service - Brakes (optional)

Apply brake pedal and check function of trailer brakes.

10 Hours Service - Air Tank for Brakes (optional)

Drain the air tank for condensed water by opening the drain valve.

50 Hours Service - Transmission Shaft

Check function and condition of the transmission shaft protection guard. Replace any damaged parts.

50 Hours Service - Wheel Nuts

Tighten wheel nuts as follows.

Torque wrench setting for mounting wheel hub to rim plate: 490 Nm.

Tightening sequence for wheel nuts: See illustration and tighten in the numbered order.

ATTENTION! When wheels has been mounted or re-tightened, the plastic nut covers must be placed on the nuts afterwards.

50 Hours Service - Air Brakes (optional)

The air brakes are checked for leaks by the following procedure:

1. Connect the snap couplers to the tractor. Fill the trailer air tanks.

2. Check for leaks with brakes released.

3. Apply the brake up to full pressure.

4. Check for leaks with brakes applied.

50 Hours Service - Tyre Pressure

Check the tyre pressure according to the table in “Technical Specifications”.

€

DANGER! Never inflate tyres more than to the pressure specified in the table. Over-inflated tyres can explode and cause severe injuries! See the section “Occasional Maintenance - Change of Tyres”.

WARNING! If renewing tyres, always use tyres with minimum load index as specified.

6 - Maintenance

100 Hours Service - Check/Adjust Drawbar (Fixed High Drawbar only)

If too many movements occur sideways, the drawbar must be adjusted.

1. Loosen counternuts (B).

2. Regulate on the turnbuckles (A) on each side to adjust and center

the drawbar.

3. Tighten counternuts (B).

250 Hours Service - Readjustment of the Boom

See section “Occasional Maintenance” on page 85.

250 Hours Service - Hydraulic Circuit

Check the hydraulic circuit for leaks and repair, if needed.

Refill nitrogen accumulators for:

• ParaLift

• Suspension (if fitted)

WARNING! Hoses for boom lifting device must be changed after every 5 years of use.

WARNING! Nitrogen accumulators may contain oil under pressure.

250 Hours Service - Hoses and Tubes

Check all hoses and tubes for possible damage and proper attachment. Replace damaged hoses or tubes.

250 Hours Service - Wheel Bearings

Check for play in the wheel bearings:

1. Place stop wedges in front of and behind the left wheel and jack up right wheel.

2. Rock the right wheel to discover possible play in the bearings.

3. If any play, support the wheel axle to prevent the trailer from falling

down from the jack.

4. Remove hub cap (A) and cotter pin (B). Turn the wheel and tighten the castle nut (C), until a slight resistance is felt in the wheel rotation.

5. Loosen the castellated nut until the first notch - horizontal or vertical - is aligned with the cotter pin hole in the shaft.

6. Fit a new cotter pin and bend it to keep it in place.

7. Fit the hub cap to the hub again.

8. Repeat the procedure for the left wheel.

6 - Maintenance

250 Hours Service - Inspect Parking Brake (optional)

Inspect the following:

Parking brake lever

If it can be pulled further backwards than 90° (midway), using a traction of approximately 25 kg, the cable needs to be adjusted.

Parking brake cable

Inspect the parking brake cables for possible wear or damages. Replace worn or damaged parts.

When the parking brake is relieved, the cable must be limp; otherwise it needs to be adjusted.

Correct length:

• When the brake is relieved, the cable must be tight and yet not stretched.

• Lengthening/shortening of the parking brake cable is carried out by adjusting the turnbuckle located inside the frame.

ATTENTION! There are two versions of the hand brake system available. One version is connected to the centre of the wheel axle (see picture to the right), the other version is connected near the wheel.

1. Once the brake lever (A) is adjusted, tighten the cable by moving the hand brake lever (B) back.

2. Tighten the bolts on the brake connector (C).

3. Fine-tuning of the hand brake can be adjusted with the cable bolt (D).

250 Hours Service - Brake Adjustment (optional)

Lift the back of the sprayer from the ground. It is recommended to use two lifting jacks, which are placed under the wheel axle. Make sure the sprayer is stable and secured before carrying out any adjustments.

ATTENTION! There are two versions of the hand brake system available, one of the pictures should show your system at hand.

1. Loosen the 4 bolts at the brake connector (C) between the brake arms. Also loosen the screw in each end of the brake connector and the hand brake cable.

2. Adjust the nut (A) counterclockwise. Turn the nut 60° (1/6 turn) at a time - alternately on both left and right brake. Continue the adjustment, until resistance occurs when rotating the hub/wheel.

3. Turn the nut 60° (1/6 turn) clockwise to loosen brake. Hub/wheel should rotate freely now.

4. Tighten the brake connector (C) bolts again.

5. Tighten the hand brake cable again - See “250 Hours Service -

Inspect Parking Brake (optional)” on page 82.

WARNING! The adjustment must be carried out simultaneously on both brakes. Therefore, adjust both left brake and right brake alternately.

6 - Maintenance

250 Hours Service - Hydraulic Brakes (optional)

Apply brakes to full pressure and inspect brake lines for damages or leaks. Replace damaged parts. If the hydraulic brake lines have been dismantled, the hydraulic circuit must be vented afterwards:

1. Loosen the brake hose at both brake cylinders.

2. Apply the brake, until oil without air bubbles comes out.

3. Tighten the brake hose, before relieving the brake again.

WARNING! Always vent the circuit, if the hydraulic brake lines have been dismantled.

1000 Hours Service - Wheel Bearings and Brakes

Check the condition of the bearings and brake wear parts in the following way:

1. Place stop wedges in front of and behind the wheel opposite to the one to be serviced (e.g.left wheel). Jack up the wheel to be serviced (e.g. right wheel).

2. Support the trailer with axle stands.

3. Remove the wheel.

4. Unscrew the 6 bolts and remove the hub cap (A), cotter pin (B) and

castle nut (C).

5. Pull off the brake drum (D). Use a wheel puller if necessary.

6. Vacuum the brake drum (D) for brake dust, or rinse it with water.

€

DANGER! Brake dust can cause severe health injuries! Avoid inhalation of brake dust! Wear a respirator when servicing the brakes. Do not clean brakes with compressed air! Use a vacuum cleaner or rinse with water to avoid brake dust being blown around.

7. Rinse the remaining parts on the brake carrier plate with water and wipe them.

8. Remove roller bearings (E), clean all parts with a degrease detergent and wipe them.

9. Check the brake drum diameter and lining thickness. Replace if worn.

Max. wear rates on brake components:

• Max. drum diameter: 302 mm (Small drums)

• Max. drum diameter: 402 mm (Large drums)

• Min. lining thickness: 2.0 mm

WARNING! The specified minimum thickness is the absolute minimum, which must never be exceeded. Replace the parts, if they would reach the above dimensions before the next service inspection.

WARNING! Renewal of brake linings or brake drums must be done for both sides at the same time.

ATTENTION! If the brake drum must be removed from the wheel hub, a hydraulic press is required to press the wheel studs out.

6 - Maintenance

10. Remove the clevis pin between the air diaphragm cylinder and the brake cam lever.

11. Remove the cotter pin (G), castle nut (F) and the brake shoe anchor bolt (H), and slide the brake shoes over the cam. Twist the pair of brake shoes to remove the shoe return springs (I). Replace the brake shoes, if the linings are worn.

12. Apply a small amount of copper paste on moving parts and reassemble the brake shoes and shoe return springs (I).

WARNING! Do not get copper paste in contact with the brake linings and drums.

13. Fit the shoe assembly with the anchor bolt (H) first. Then pull the shoes away from each other and slide them over the cam afterwards. Tighten the anchor bolt castle nut (F) again, and fit a new cotter pin (G).

14. Check roller bearings for discolouration and wear. Replace if worn or damaged.

15. Assemble drum (D) and bearings (E) using a new sealing ring (J ).

16. Fill the hub and bearings with new grease, before fitting them to the wheel axle.

WARNING! Do not get oil or grease in contact with the brake linings and drums.

17. Fit the castle nut (C). Rotate the brake drum (D) and tighten the castle nut (C), until a slight rotation resistance is felt.

18. Loosen the castle nut (C) again, until the first notch is aligned with the cotter pin hole in the axle.

ATTENTION! The shaft has a vertical and an horizontal cotter pin hole. Use the one first aligned with the notch when loosening the castle nut.

19. Fit a new cotter pin (B) and bend it to keep it in place.

20. Fit the hub cap (A) to the hub. Slightly tighten the 6 bolts.

21. Adjust the brakes as described in “250 Hours Service - Brake Adjustment (optional)” on page 82.

22. Fit the wheel again and tighten the wheel nuts. See “50 Hours Service - Wheel Nuts” on page 80 regarding torque

wrench setting. Tighten all bolts to half the specified torque at first, then tighten to the full specified torque.

23. Tighten again after 10 hours of work. Check the torque every day, until it is stabilised.

If you do not feel totally confident changing wheel bearings or brakes, then contact your HARDI dealers workshop.

6 - Maintenance

Occasional Maintenance

General Info

The maintenance and service intervals for the following components will depend very much on the conditions, under which the sprayer is operated, and therefore it is almost impossible to specify the intervals.

Pump Valves and Diaphragms Renewal

Pump model: 363 and 463.Diaphragm pump overhaul kit (valves, seals, diaphragms etc.) can be ordered. Detect the pump model - the overhaul kit can be ordered by your local dealer.

Model 363: Item no. 75073700

Model 463: Item no. 75073900

Val ves

Remove valve cover (1) before changing the valves (2) - note their orientation, so that they are replaced correctly!

ATTENTION! A special valve with white flap (2A) is used at the two upper side inlets. It has to be placed in the valve openings as shown. All others are the type with black flap. It is recommended to use new gaskets (3), when changing or checking the valves.

Diaphragms

Remove the diaphragm cover (4). The diaphragm (5) may then be changed. If fluids have reached the crankcase, re-grease the pump thoroughly. Also check that the drain hole at the bottom of the pump is not blocked.

Reassemble the pump with the following torque setting.

Diaphragm cover: 90 Nm.

Diaphragm bolt: 90 Nm.

ATTENTION! Before tightening the 4 bolts for the diaphragm cover (B), the diaphragm must be positioned between centre and top to ensure correct sealing between diaphragm pump housing and diaphragm cover. Turn the crank shaft if necessary.

6 - Maintenance

Level Indicator Adjustment

The level indicator reading should be checked regularly. When the tank is empty, the float should lie on the stop pin (D) of the rod, and the Oring on the indicator should be positioned at the top position line (A).

If any deviation is found, do the following:

1. Pull out the plug (B).

2. Loosen screws (C).

3. Adjust the length of the cord, until it reads correctly.

4. Push the plug (B) back into place.

NOTE! To obtain the best accuracy, the adjustment shall be done with the sprayer attached to the tractor normally used.

Level Indicator Cord Renewal

If the cord on the level indicator has to be changed, the float guide pole is removed:

1. Remove the tank drain valve (see the following section “Drain Valve Seal Replacement”) and loosen the fitting holding the pole in position.

2. Pull the pole down through the drain valve hole, until it is free in the top of the tank.

3. The pole can now be taken out of the tank through the filling hole.

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DANGER! Do not enter the inside of the tank - the parts can be changed from the outside of the tank!

Drain Valve Seal Replacement

If the main tank drain valve leaks, the seal and seat can be changed in the following way.

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DANGER! Do not enter the inside of the tank - the parts can be changed from the outside of the tank!

WARNING! Use eye / face protection mask, when dismantling the tank drain valve!

1. Make sure that the tank is empty and clean.

2. The valve must be closed and the string must be loose.

3. Pull out the clip (A) and pull down the connecting piece (B). The

entire valve assembly can now be pulled out.

4. Check cord and valve flap assembly (C) for wear, replace seal (D) and reassemble.

5. Reassemble the valve using a new valve seat (E). Lubricate O-rings (F) before assembly.

6. Fit clip (A) again.

ATTENTION! Check the valve function using clean water, before filling chemicals into the tank.

6 - Maintenance

Nozzle Tubes and Fittings

Poor sealings are usually caused by:

• Missing O-rings or gaskets

• Damaged or incorrectly seated O-rings

• Dry or deformed O-rings or gaskets

• Foreign objects

In case of leaks:

DO NOT overtighten. Disassemble, check condition and position of Oring or gasket. Clean, lubricate and reassemble.

The O-ring must be lubricated ALL THE WAY ROUND, before fitting it on to the nozzle tube. Use non-mineral lubricant.

For AXIAL connections, a little mechanical leverage may be used.

For RADIAL connections, only tighten by hand.

Adjustment of 3-Way Valve

The large ball valve (type s93) can be adjusted, if it is too tight to operate - or if it is too loose (=liquid leakage).

• Correct setting is when the valve can be operated smoothly by one hand.

Use a suitable tool and adjust the toothed ring inside the valve as shown on the drawing.

ATTENTION! The small ball valves (type s67) cannot be adjusted.

Retighten the Frame

The frame are two sections bolted together. Also the drawbar is bolted to the frame. These bolts need to be tightened correctly. Check regularly if bolts are tightened according to the specified torques below.

180 Nm

250 Nm

180 Nm

6 - Maintenance

Readjustment of Boom - General Info

Before commencing adjustment jobs, please go through this check list.

1. The sprayer must be well lubricated (see section about lubrication).

2. Connect the sprayer to the tractor.

3. Place tractor and sprayer on level ground (horizontal).

4. Unfold the boom.

5. Set slanting angle to neutral position (horizontal).

ATTENTION! For information on boom terminology, see “Boom and terminology” on page 29.

NOTE! Adjustment of hydraulic cylinders is to be carried out without pressure in the system.

WARNING! No one is allowed under the boom, whilst the adjustment is carried out.

Alignment of inner and 1st outer wings

The inner wing sections must be aligned with the 1st outer wing sections. If necessary adjust the inner wing sections as follows:

1. Depressurize the folding cylinders.

2. Loosen counter nuts (A) and (C).

3. Loosen the screws (B).

4. Adjust the rigging screw (D) until the correct setting is reached.

5. Adjust the stop screws (B) up against the inner section.

6. Tighten counter nuts again.

7. Check the alignment. If needed, redo the adjustment described

above.

ATTENTION! The rigging screw (D) must be slightly over tightened/adjusted to insure a firm and fixed outer section.

6 - Maintenance

Alignment of 1st outer and 2nd outer wings

The 2nd outer wings must be aligned with the 1st outer wings. If necessary adjust the 2nd outer wings as follows:

1. Depressurize the folding cylinders.

2. Loosen counter nuts (A) and (C).

3. Loosen the screws (B).

4. Adjust the rigging screw (D), until the nozzle sections are aligned

with each other.

5. Adjust the stop screws (B) up against the inner section.

6. Tighten counter nuts again.

7. Check the alignment. If needed, redo the adjustment described

above.

ATTENTION! The rigging screw (D) must be slightly over tightened/adjusted to insure a firm and fixed outer section.

Breakaway section adjustment

The breakaway section must release when a force of approximately 150 N (15 kg) is applied to the extremity of the breakaway section. If necessary, the release force is adjusted as follows:

1. Make sure that claw coupling is correctly lubricated.

2. Loosen the counter nut (A).

3. Adjust the nut (B), until the breakaway will release at a force of 150

N (15 kg) applied at the extremity of the section.

4. Tighten the counter nut again.

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DANGER! Never place fingers into open breakaway clutch! You may be injured, if the clutch snap closes by accident!

WARNING! Do not tighten the breakaway clutch more than necessary. Over-tightening can cause damage to the boom.

End stop valves

The end stop valve activates/disables the folding/unfolding of the boom.

Inspect with the 1st and 2nd outer wings in folded position, and with the 1st outer and inner wing sections in folded position. The distance between the bolt head (A) and the surface (B) of the cylinder is 3 mm. Adjust position of bolt (A) if necessary.

6 - Maintenance

Wing tilt adjustment

The horizontal adjustment of the wings is carried out by the retracted tilt cylinder. The boom must be straight and horizontal. If necessary, adjust the wing as follows:

1. Support the boom to relieve the load from the hydraulic cylinder.

2. Loosen counter nut (A), which is positioned by the hinge ring on

the cylinder’s piston rod.

3. With a wrench (on two flat spots on end of the ram), adjust the cylinder ram inwards or outwards to get the desired wing level.

4. Repeat the steps for the other side.

Slanting Indicator Adjustment (optional)

If the position of the pointer on the indicator does not correspond to the actual boom position, the pointer (A) can be adjusted.

1. Loosen the small bolt (B) sufficiently to allow the wire (C) to be adjusted.

2. Place the pointer (A) in correct position and fasten bolt (B) against the wire (C) again.

Wear Bushing Replacement on Boom Lift

The wear bushes are inspected and renewed, before they are worn through.

1. Connect the trailer to a tractor and unfold the boom to working position.

2. Lift the boom centre frame with a lifting device and support it, until the load is taken off the parallelogram arms.

3. Remove the screws (A), and pull out the pins (B) at one of the upper parallelogram arms and replace the wear bushes.

4. Refit the arm.

5. Repeat this on the other upper arm.

6. The lower arms must be disconnected simultaneously

7. Apply grease into all grease nipples.

8. Remove the lifting gear again.

Change of Bulbs

1. Switch off the light.

2. Loosen the screws on the lamp and remove the cover or lens.

3. Remove the bulb.

4. Fit a new bulb, refit the cover and tighten the screws.

ATTENTION! If halogen bulbs are used, never touch the bulb with your fingers. Natural moisture in the skin will cause the bulb to burn out, when the light is switched on. Always use a clean cloth or tissue when handling halogen bulbs.

6 - Maintenance

Wear Bushing Renewal on Steering

If too much play is found in the steering, the wear bushes must be replaced. This should be done at your local HARDI dealer.

Venting the Steering Hydraulics

If the steering cylinder hydraulics have been dismantled, it is necessary to vent the cylinders. Depending on the sprayer size, the venting screws (A) are installed as shown on the pictures.

1. Remove the dust cap from the venting screw (A) on the left side steering cylinder.

2. Mount a clear 5 mm hose to the venting screw and lead it into a catch can.

3. Open the venting screw 1/8 turn and then steer fully to left (retract cylinder).

4. Hold the steering position, until air is no longer visible in the hose.

5. Close the venting screw (A) again.

6. Repeat the procedure for the right side cylinder.

7. Steer fully from left to right 8-10 times.

8. Complete the venting procedure again to ensure that there is no

air in the system.

9. Mount the dust caps onto the venting screws again.

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DANGER! Be careful when operating the steering! Make sure that there is space enough to steer the sprayer from side to side! Only persons working on the sprayer is allowed in the moving area of the sprayer!

Suspension Rubber Dampers (optional)

If the shock absorbers loose their efficiency, they should be replaced.

1. Connect the sprayer to a tractor to prevent overbalancing.

2. Lift the rear end of the sprayer with e.g. a crane. Use lifting points as described in “Sprayer setup”.

3. Loosen the nut below the suspension rubber dampers.

4. Remove the suspension rubber dampers and replace with new ones.

5. Tighten the nut below the suspension rubber dampers.

6. Lower the rear of the sprayer again.

Shield Replacement on Transmission Shaft

• See the manufacturer’s instruction book.

Replacement of Transmission Shaft Cross Journals

• See the manufacturer’s instruction book.

6 - Maintenance

Change of Tyres

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DANGER! If it is time to change tyres, it is recommended to leave this job to a specialist and follow the rules below. Some mounting instructions are usually printed on the tyre itself.

• Always clean and inspect the rim before mounting a new tyre.

• Always check that the rim diameter corresponds exactly to the rim diameter moulded on the tyre.

• Always inspect the tyre inside for cuts, penetrating objects or other damages. Repairable damages should be repaired

before installing the tube. Tyres with non-repairable damages must never be used.

• Also inspect the tyre inside for dirt or foreign objects. Remove this before installing the tube.

• Always use tubes of recommended size and in good condition. When fitting new tyres, always fit new tubes.

• Before mounting, always lubricate both tyre beads and rim flange with approved lubricating agent or equivalent

anticorrosion lubricant. Never use petroleum based greases and oils, because they may damage the tyre. Using the appropriate lubricant will prevent the tyre from slipping on the rim.

• Always use specialised tools for mounting the tyres as recommended by the tyre supplier.

• Make sure that the tyre is centred, and that the beads are perfectly seated on the rim. Otherwise tearing of the bead

wire may occur.

• Inflate the tyre to 1-1.3 bar (14.5-19 psi), then check whether both beads are seated perfectly on the rim. If any of the beads do not seat correctly, deflate the assembly and re-centre the beads, before starting inflation of the tyre. If the beads are seated correctly on the rim at 1-1.3 bar (14.5-19 psi), inflate the tyre to a maximum of 2.5 bar (36 psi), until they seat perfectly on the rim.

• Never exceed the maximum mounting pressure moulded on the tyre!

• After mounting tyres adjust inflation pressure to operation pressure recommended by the tyre manufacturer.

• Do not use tubes in tubeless tyres.

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DANGER! No observance of mounting instructions will result in a bad seating of the tyre on the rim, and it could cause the tyre to burst leading to serious injury or death! DANGER! Never mount or use damaged tyres or rims! Use of a damaged, ruptured, distorted, welded or brazed rim is not allowed!

6 - Maintenance

IntelliTrack Front Potentiometer Calibration

If the IntelliTrack front potentiometer on the drawbar can not be mounted correctly (with the bar not perpendicular to drawbar), then the following must be done.

1. Align the drawbar by measuring the blank part of the hydraulic cylinder pistons. The sprayer’s drawbar is aligned, when the two cylinder pistons have the same length, plus/minus 2 mm. Adjust with manual track button on the controller.

2. Place the transverse potentiometer bar absolutely perpendicular to the drawbar.

3. Go to menu 4.7 in the controller, and check if the potentiometer reading F is 2.50 Volt.

4. Adjust the potentiometer housing, until the controller reads 2.50 Volt.

5. Tighten the potentiometer body screws again.

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6 - Maintenance

Safety Valve Activation

To make the fluid system work perfectly over time, it is good practice to regularly provoke opening of the safety valve.

This avoids clogging and ensures proper function of the safety valve. Opening of the valve is done by turning the pressure SmartValve to “Pressure draining” or an unused function, when the pump is running. This is good practice for all sprayers, but particularly for sprayers without optional equipment.

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DANGER! Before turning pressure SmartValve to “Pressure draining”, it is very important to be sure that the quick coupler lid is correctly and completely mounted to the filling stud in its locked position. Failure to do so causes a risk of contamination and injury from the quick coupler lid being “shot” off when pressurized! If it is not possible to mount lid completely, lubricate the rubber seal and the grip hooks.

6 - Maintenance

Off-Season Storage

Off-Season Storage Program

To preserve the sprayer intact and to protect its components, the following off-season storage program is carried out.

Before storage

When the spraying season is over, you should devote some extra time to the sprayer. If chemical residues are left over in the sprayer for longer periods, it may reduce the life of its individual components.

1. Clean the sprayer completely - inside and outside - as described under “Cleaning” on page 69. Make sure that all valves, hoses and auxiliary equipment have been cleaned with detergent and flushed with clean water afterwards, so that no chemical residues are left in the sprayer.

2. Replace any damaged seals and repair any leaks.

3. Empty the sprayer completely, and let the pump work for a few minutes. Operate all valves and handles to drain as

much water off the spraying circuit as possible. Let the pump run until air comes out of all nozzles. The rinsing tank is also drained.

4. Pour approximately 50 litres of antifreeze mixture, consisting of 1/3 anti-freeze and 2/3 water, into the tank.

5. Engage the pump and operate all valves and functions, operating unit, chemical inductor etc., allowing the antifreeze

mixture to be distributed around the entire circuit. Open the operating unit main valve ON/OFF and distribution valves, so that the antifreeze is sprayed through the nozzles as well. The antifreeze will also prevent O-rings, seals, diaphragms etc. from drying out. On sprayers with a FlexCapacity pump, this must also be engaged and flushed.

6. Lubricate all lubricating points according to the lubricating intervals.

7. When the sprayer is dry, remove rust from scratches or damage in the paint, if any, and touch up the paint.

8. Remove the glycerine-filled pressure gauges and store them frost-free in vertical position.

9. Apply a thin layer of anti-corrosion oil (e.g. SHELL ENSIS FLUID, CASTROL RUSTILO or similar) on all metal parts. Avoid

oil on rubber parts, hoses and tyres.

10. Fold the boom in transport position and relieve pressure from all hydraulic functions.

11. All electric plugs and sockets are to be stored in a dry plastic bag to protect them against moisture, dirt and corrosion.

12. Remove the control boxes and computer display from the tractor. Store them dry and clean (indoor) in a non-

condensing environment.

13. Wipe hydraulic snap-couplers clean and fit the dust caps.

14. Apply grease to all hydraulic ram piston rods, which are not fully retracted in the housing, to protect against corrosion.

15. Chock the wheels, to prevent moisture damage and deformation of the tyres. Tyre blacking can be applied to the tyre

walls to preserve the rubber.

16. Drain air brake tank for condensed water.

17. To protect against dust, the sprayer can be covered by a tarpaulin. Ensure ventilation to prevent condensation.

6 - Maintenance

After storage

After a storage period, the sprayer should be prepared for the next season the following way:

1. Remove the tarpaulin.

2. Remove the support for the wheel axle, and adjust the tyre pressure.

3. Wipe off the grease from hydraulic ram piston rods.

4. Fit the pressure gauges again. Seal with Teflon tape.

5. Connect the sprayer to the tractor, including hydraulics and electrics.

6. Check all hydraulic and electric functions.

7. Empty the tank for remaining antifreeze.

8. Rinse the entire liquid circuit of the sprayer with clean water.

9. Fill with clean water and check all functions.

10. Check function of the brakes. Please note that brake power will be reduced, until the rust is worn off the drums. Always

brake lightly until the drums are clean.

7 - Fault finding

Operational Problems

General Info

Operational incidents are often due to the same reasons:

• A suction leakage reduces the pump pressure and may interrupt suction completely.

• A clogged suction filter may damage suction or interrupt and prevent the pump from running normally.

• A clogged pressure filter increases pressure in the fluid system in front of the pressure filter. This may blow the safety

valve.

• Clogged in-line filters or nozzle filters increase pressure in the pressure gauge, but it decreases pressure at the nozzles.

• Impurities sucked in by the pump may prevent the valves from closing correctly, thus reducing the pump flow.

• A bad reassembly of the pump elements, especially the diaphragm covers, causes air intakes or leaks and reduces the

pump flow.

• Rusted or dirty hydraulic components cause bad connections and early wears.

• A poorly charged or faulty battery causes failure and misbehaviour in the electrical system.

Therefore ALWAYS check that

• Suction and pressure filters, as well as nozzles, are clean.

• Hoses are free of leaks and cracks, especially suction hoses.

• Gaskets and O-rings are present and in good condition.

• Pressure gauges are in good working order. Dosage accuracy depends on it.

• Operating unit functions properly. Use clean water to check.

• Hydraulic components are clean.

• The tractor battery and its connectors are in good condition.

7 - Fault finding

Liquid System

FAULT PROBABLE CAUSE CONTROL/REMEDY

No spray from boom when turned on. SmartValve positions are wrong. Set correct valve positions for spraying.

Suction/pressure filters are clogged. Clean suction and pressure filters.

No suction from tank. See if suction fitting in main tank sump is free of

sedimentation. Clean if needed.

Lack of pressure. Incorrect assembly. Boost valve is open.

Air in system. Fill suction hose with water for initial priming.

Too much agitation. Close the agitation valve.

Pump valves are blocked or worn. Check for obstructions and wear.

Blocked filters Clean all filters.

Defective pressure gauge. Check for dirt at inlet of pressure gauge.

Pressure dropping. Filters are clogging. Clean all filters. Fill with cleaner water. If using

powders, make sure agitation is on.

Nozzles are worn. Check flow rate. Replace nozzles, if it exceeds 10%.

Sucking air towards end of tank load. Lower pump speed (rpm).

Pressure increasing. Pressure filters beginning to clog. Clean all filters.

Formation of foam. Air is being sucked into system. Check tightness/gaskets/O-rings of all fittings on

suction side.

Excessive liquid agitation. Lower pump speed (rpm).

Check safety valve is tight.

Ensure returns inside the tank are present.

Use a foam damping additive.

Liquid leaks from bottom of the pump. Damaged diaphragm. Replace diaphragm. See relevant section.

Vibrations in system and unpleasant noise from the pump.

Air is being sucked into system. Check for leaks, holes in hoses, tightness/gaskets/O-

rings of all fittings on the suction side.

Operating unit is not functioning, or it is having a malfunction.

Blown fuse(s). Check mechanical function of micro switches. Use

cleaning/lubricating agent if the switch does not operate freely.

Check motor current, max. 450-500 mA. If over, change the motor.

Wrong polarity. Brown to positive (+). Blue to negative (-).

Valves not closing properly. Check valve seals for obstructions.

Check micro switch plate position. Loosen the screws holding the plate a 1/2 turn.

No power. Wrong polarity. Check that brown is positive (+), blue

is negative (-).

Check print plate for dry solders or loose connections.

Check fuse holder is tight around fuse.

7 - Fault finding

Hydraulic System, Z-boom version

IntelliTrack

FAULT PROBABLE CAUSE CONTROL/REMEDY

No boom movements when activated. Insufficient hydraulic pressure. Check oil pressure.

Check tractor hydraulic oil level.

Insufficient oil supply. Oil flow must be min. l/min. and max. 130 l/min.

Check tractor hydraulic oil level.

Blown fuse(s). Check / replace fuse in junction box.

Bad / corroded electrical connections. Check / clean connections, multi plugs etc.

Insufficient power supply. Voltage on activated solenoid valve must be more

than 8 volts.

Use wires of at least 4 mm for power supply.

Defective relay / diodes in junction box. Check relays, diodes and soldering at PCB in junction

box. LED diodes indicate boom functions.

Clogged restrictors in bypass block. Remove and clean restrictors in bypass block (See

hydraulic diagram). Change hydraulic oil + filter.

Wrong polarity. Check polarity. Red positive (+), black negative (-).

ParaLift lock does not lock.

Boom lift raises to max. position, when tractor hydraulics are engaged.

Back pressure in return line exceeds 15 bar. Connect the return line with a free flow to hydraulic oil

reservoir.

Divide return line in two and lead return oil back to reservoir via two spool valves.

Oil heats up in Closed Centre systems. Bypass valve does not close properly. Check / close (screw in) by-pass valve.

Internal leaks in flow regulator. Replace flow regulator O-rings and backup rings.

Replace flow regulator.

Individual hydraulic piston does not move. Clogged restrictor. Dismantle and clean restrictor.

FAULT PROBABLE CAUSE CONTROL/REMEDY

IntelliTrack steers slowly or erratically. Air in system. Vent the Intellitrack cylinders - see “Venting the Steering

Hydraulics”

Front potentiometer bar/springs move erratically.

Re-arrange the spring setup, so that the potentiometer bar moves freely.

IntelliTrack has non-linear steering or is not following the tractor’s track.

Front potentiometer springs are not parallel. Refit springs to parallel position and check potentiometer

reading - see “IntelliTrack Front Potentiometer Calibration”.

7 - Fault finding

100

Mechanical problems

Emergency Operation - Hydraulics

In case of power failure, the damper control can be operated as follows:

1. Remove plastic cover (A) from valve (B).

2. Pivot valve (B) inward.

Emergency Operation - Liquid system

In case of power failure, it is possible to operate all functions of the operating unit manually. First disconnect the multi-plug from the control box. Now manually turn the emergency control knobs.

The problem may be due to a blown fuse. A fuse is placed inside the box. Fuse type: Thermo.

Hardi NAVIGATOR FORCE Instruction Book

Specifications and Main Features

Frequently Asked Questions

User Manual